2/07/2010 1

CLIC Permanent Magnet Quadrupole

Engineering Development

Norbert Collomb, STFC Daresbury Laboratory

N. Collomb

2/07/2010 2

CLIC Permanent Magnet Quadrupole• Revisit points from last meeting• Engineering specification• Principle evaluation• Schematics for 3 options• Model 5.53 for smaller envelope• Discussion with manufacturers and suppliers• Automation for high volume production• Next steps

– Detail design of one or two options– Finite Element Analysis to predict performance compliance– Programme

• Summary

N. Collomb

2/07/2010 3

Previous meeting points• Movement principles – Linear Motion Ball screw system• Option 5.19 to be developed further• Confirmation of envelope (supply of CAD info for module to

corroborate constraints)• Revisit existing design according to above point• Manufacturer discussion

– Motor– Gearbox– Backlash coupling– Ball Screw and Nut– PM material and manufacture

• Specifications for components above• Integration of components into CAD model and CAD QA• Next steps

N. Collomb

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Option 5.19 previous Schematic

N. Collomb

60mm position (approx. 30T/m)

60mm from full gradient position Linear Actuator or

Screw-jack

“Faceplate” to hold yokes in position

Permanent Magnet (black)

Linear Friction strips

“Support pillars”

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Option 5.19 previous summary

• Can be made to fit into specified envelope (just).• Then ‘Current’ design indicates height as 526mm and width as 410mm• Mechanism design is being revised as we speak (done, need validation)• First indications:

– Requires independent halves (we assume this is still the case)– Two linear actuators or jack screws essential (jack screws not sufficiently

accurate and force design to exceed envelope)– Requires linear encoder to provide feedback for synchronisation (can be

eliminated using Stepper motors)– PM enclosure contains bearing system to eliminate 5 D.O.F. Still applicable

• The solution currently under investigation needs careful design• The design must definitely be validated by Finite Element Analysis and

prototyping

Despite being mechanically more challenging than solutions 5.21 and 5.20, the magnetic characteristics favour this solution. Decided to pursue this option further.

N. Collomb

2/07/2010 6N. Collomb

MB QUAD

ACCELER. STRUCTURE(BRAZED DISKS)

RF DISTRIBUTION

GIRDER

CRADLE

VACUUM MANIFOLDS

ALIGNMENT SYSTEM

BEAM INSTRUMENTATION

DB QUAD

COOLING CIRCUITS

RF LOAD

PETS ( OCTANTS, MINI-TANK )

RF SPLITTER W/ CHOKE-MODE FLANGE

Drive beam 100 A

PETS ON-OFF MECHANISM

Main beam ~1 A

WAKE-FIELDMONITOR

Module CAD Info image

2/07/2010 7N. Collomb

Option 5.19 current Schematic

Gearbox (Planetary)

Stepper motor

Backlash coupling

Ball Screw 1605-5

Ball Screw Nut (preloaded)

Faceplate with Linear Cross Roller bearing preload features

Linear Cross Roller Bearing system

Height: 466 mm

Width: 340 mm

Length: 270mm

2/07/2010 8N. Collomb

Option 5.19 current Schematic

Magnet Aperture Ø28 mm

Aluminium Support Pillars fastened to yoke

Face-plate fastening holes

Diamond dowel Split line, top - bottom

Permanent Magnet moving up and down to adjust field

‘Cantilever’ arm bonded to PM

75 mm max.

25 mm

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Engineering SpecificationSufficient info to discuss specification with manufacturer• Static Force of 3.2 kN to overcome• Stroke of 75 mm• Accuracy from CERN document and Ben’s gradient graph equates to 15 μm

repeatability, including ‘creep’ and ‘backlash’.• Motor should operate on 12/24V DC preferably and be of the Stepper type using

400 true steps per revolution, mounting with flange or collar.• Gearbox should be low or preferably no backlash type (Planetary preferred) and the

ratio in conjunction with the motor accuracy and lead screw pitch has been worked out to be 30:1

• The Ball screw and Nut need to be pre-loaded and the accuracy to C1 over the stroke length. The forces in the system indicate a diameter of 16 mm with a 5 mm lead (pitch). Validation required via FEA.

• Envelope constraints for drive system: length 255, width 135 and depth 55 mm• Materials of low magnetic permeability are to be used where possible and plastics

need to be radiation resistant if absolutely needed.• Stepper motors use permanent magnets and we need to evaluate their influence on

the field of the Quad and function of the motor.

N. Collomb

29/04/2010 10

Principle Evaluation• Version 5.19 schematic fits inside envelope• Envelope: 391 (W) x 471 (H) x 270 (L) mm• Movement range covers 120 – 7% requirement,

provided we use a family of three, i.e. 120 – 49%, 93 – 28% and 66% - 7%

• Accuracy can be achieved (pending feedback from manufacturer)

• Repeatability depends on home position, must provide map of position vs field

• Synchronisation not as much an issue as initially thought

N. Collomb

29/04/2010 11

Schematic for 3 options• Family of three range,

– 120 – 49%,– 93 – 28% and– 66% - 7%

• Achievable by reduction in length• Components remain the same (provisional)• Height and width remain the same (provisional)• Accuracy and repeatability remain the same

(assumed)• Synchronisation equally (in)sensitive across range• Map required with range adjusted accordingly.

N. Collomb

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5.53 Model for smaller envelope

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Height: 390 mm

Width: 340 mm

Length: 270mm

Ferromagnetic Steel enclosure with 20mm thickness walls

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5.53 Model for smaller envelope

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Least gradient position

45mm

Maximum gradient position

Permanent Magnet moves as per Option 5.19

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Manufacturer and supplier discussions

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Magnet manufacturer discussion’s have continued and we are expecting information on queries very soon. Especially on the latest development for the PM Quadrupole.

29/04/2010 15N. Collomb

Manufacturer and supplier discussionsLinear motion system:

As per specification in previous slide, we had invited a manufacturer to supply the following components:

1. Motor (advice was provided on Stepper and Servo motor)2. Gearbox (manufacturer recommended Planetary system based on requirements)3. Backlash coupling (not usually supplied by manufacturer, but may be build in)4. Ball Screw and Nut (discussed accuracy and repeatability – will provide advice

from HQ engineers)5. Brake (it is envisaged to incorporate this in the motor/gearbox)

The manufacturer has been requested to provide a cost effective solution and look at ‘off-the-shelf solutions first.The brake has a double function in terms of ‘creep’ and fail safety. Information has been requested from their head office engineers.Should we pursue solution 5.19 (5.53) then the effects of the PM material in the Quad on the Stepper motor (and vice versa) need to be investigated further.Radiation is an unknown for the manufacturer, however they are investigating this in general terms at their head office.

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Automation for high volume production (unchanged)

• Draw up manufacturing and assembly process flow chart

• Identify areas that can be automated• Design of jigs and fixtures to assemble components• Design Quality Control process and required

hardware for testing• Establish safe working procedures

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Next steps: Design• Complete system schematic for solution 5.19 (complete)• (Re-)Evaluate magnet design and decide on one or two

solutions (complete)• Develop the solution(s) in detail• Carry out Finite Element Analysis to evaluate and validate

component and assembly stresses remain within acceptable limits

• Complete detail design and carry out cost analysis

– A summer student has commenced work on 5.53.

Expected design duration: 4 months (includes new mechanism design for new quad option)

N. Collomb

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Next steps: Manufacture

• Request quotes from manufacturers• Discuss process if required and associated

tolerances (in progress)• Agree price and lead times• Discuss possibility of supplying part assemblies (in

progress)

Expected manufacturing duration: 6 months

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Next steps: Assembly• Assemble manufactured components• Analyse assembly process and identify automation

processes• Write assembly procedure• Identify jigs and fixtures required for assembly process

Expected assembly duration: 2 months

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Next steps: Testing• Identify required instruments and measurement

equipment (manual and automated)• Measure magnetic characteristics• Measure mechanical tolerances• Specify ‘Go and No-Go’ criteria• Mark up any deviation for installation purposes• Rework or adjust if required• Create map of position versus field strength

Expected testing duration: 3 months

Prototype completion expected within: 15 months

N. Collomb

2/07/2010 21

CLIC PM Quadrupole summary• Solutions exist – need to decide on one to develop in more detail• James Richmond (Summer student) may help in reducing the design time. He

is competent in CAD and with guidance can provide design suggestions/solutions. Part of his appointment is the task of carrying out the Finite Element Analysis of components and assemblies to validate the design.

• Solution(s) need to be validated through analysis and ultimately prototype(s)• Time scale:

– Design: 4 months (unchanged, pending version decision)– Manufacture: 6 months– Assembly: 2 months– Testing: 3 months– Total: 15 months

• Procedures and processes (automation) need to be established for mass production

• Cost analysis for manufacture, assembly and testing as primary contributor needs to be carried out

• Commissioning, Installation, Maintenance and operation costs can be estimated as secondary overall contributor

N. Collomb