Marion M. White Undulator Procurement and [email protected] 07-09 February 2006 DOE Mini-Review Undulator Magnets and Supports 20 February 2006

Marion M. White

Undulator Procurement and Testing [email protected]

07-09 February 2006 DOE Mini-Review

Undulator Magnets and Supports

20 February 2006APS All Hands Meeting

Long-Lead Procurements Titanium Strongbacks 1.04.03.03.01 Magnet Blocks 1.04.03.03.02 Magnet Poles 1.04.03.03.03 1st-Article Undulator Assemblies

1.04.03.03.04

Single Undulator Test

Marion M. White



Undulator Magnets & Supports Team (significant % but none full time)

Michael BrackenLoretta CokeleyJeff Collins Alex DidenkoPatric Den Hartog*Mark Erdmann Horst FriedsamGlen Lawrence Dan NocherTom PowersBrain RusthovenSushil Sharma*Emil Trakhtenberg

Kurt BoersteRoger DejusElizabeth Moog*Shigemi SasakiKen ThompsonJanet WernerIsaac VassermanDana Capatina (DD)Ron Kmak (DD)Thomas Barsz (QA)Marion White (CAM)

* = Group Leader

Marion M. White



LLP – Titanium Strongbacks

Require forty (40) 3.4-m-long titanium bars: Forged, annealed, vibration-stress-relieved, rough machined, vibration-stress-relieved, precision machined, inspected…

Competitively bid and awarded to two vendors to reduce risk:

Metalex [Blue Ash, OH]

Dial Machine [Rockford, IL]

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LLP - Titanium Strongback 1.04.03.03.01

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LLP – 40 Titanium Strongbacks

Total cost about 4M$ Some growth in the raw materials cost was anticipated – but…

All material is under contract, but finding it...

95% of titanium is used to make pigment; only about 5% is made into metal; titanium supplies are under very high pressure due to:

Civilian and military aircraft, other military applications, a very hot market in Asia…

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Excellent Work by Metalex – 1st Article was site-accepted by ANL on 17 October 2005

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Rough Machining #2 @ Metalex - 10th October

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01 Feb: Metalex is ahead of scheduleS/N: 5A06990-02 Complete and Staged for AssemblyS/N: 5A06990-04 Complete and Staged for AssemblyS/N: 5A06990-06 Complete and Staged for AssemblyS/N: 5A06990-08 Complete and Staged for AssemblyS/N: 5A06990-10 Complete and Staged for Assembly S/N: 5A06990-12 Complete and Staged for Assembly S/N: 5A06990-14 Complete and Staged for AssemblyS/N: 5A06990-16 Complete and Staged for Assembly

(The P3 date for #16 is May 24th 2006)

S/N: 5A06990-18 At machining Oper#100S/N: 5A06990-20 At machining Oper#100S/N: 5A06990-22 At machining Oper#100S/N: 5A06990-24 At machining Oper#100

Marion M. White



Metalex – Forging Deliveries

ATI Wah Chang plans delivery of the balance of (8) forgings to Metalex:

(4) by the end of February 2006.(4) by the end of March 2006.

We are keeping a close eye on this, but they are so far ahead of schedule that it is unlikely to be a problem.

Marion M. White



10 forgings in house now. The remaining 10 are slated for shipping to Dial on Feb 20th, 2006.Processing Strongbacks: rough machine, semi machine, drill, & tap; then inspect on the CMM before final dust mill of channel surfaces. They will inspect, clean, deburr, and prepare for shipment; they expect to ship #3 to Hi-Tech about Feb 13th, and then about one per week for four weeks. Their bottleneck is in waiting for inspection.

P3 Date Dial Date Status 07 Feb 2006

#3 13 Jan. 2006 06 Feb. 2006 ANL Accept 07 Feb. 2006#5 13 Feb. 2006 10 Feb. 2006 machined, wait for insp.#7 14 Mar. 2006 17 Feb. 2006 machined, wait for insp.#9 12 Apr. 2006 24 Feb. 2006 machined, wait for insp.

Titanium Strongbacks – Progress@Dial1st Article – site-accepted - 10 Nov 2005

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First-Article Strongback Site-Acceptance at Dial Machine, Rockford, IL – Well done !!!

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Titanium Strongbacks – Progress@Dial - roughing

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Magnet Blocks 1.04.03.03.02

19,200 Neodymium Iron Boron magnet blocks - about 1M$.

Magnets are fabricated in Shin-Etsu’s Takefu Plant in Japan, ground to final precise dimensions, plated for surface protection, magnetized, labeled, sorted by magnetic field, and divided into undulator-sized lots. http://www.shinetsu-rare-earth-magnet.jp/e/masspro/index.shtml details the process.

Precise sorting by magnetic field must be done, then a spreadsheet is given to the assembly vendors listing the magnet serial number and orientation for each magnet in each slot.

Marion M. White



LLP - Magnet Blocks 1.04.03.03.02Initial problems

More shrinkage than anticipated

Problem with Ni plating

Magnets packed with Ink wet

All resolved

10 sample magnets from 1st two lots were tested

Magnetic & dimensional measurements were verified.

Lots 3&4: approved to ship

Lots 5&6: samples selected and shipped to ANL

ANL magnet expert visited Shin-Etsu 24-26 Jan.

Magnetic verification of the first sample lot of magnets at APS

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1st 2 Lots: Magnet Blocks look good

1.21

1.215

1.22

1.225

1.23

1.235

1.24

1.245

1.25

1 2 3 4 5 6 7 8 9 10

M [T]

MT_ShinEtsu

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

1 2 3 4 5 6 7 8 9 10

angle [deg]

ShinEtsu (deg)

Field measurement of first 10 blocks compared to the measurements from Shin-Etsu. The slight reference offset is understood.

Angular direction measurement of the first 10 blocks compared to the measurements done by Shin-Etsu

Marion M. White



Schedule - Magnet Blocks 1.04.03.03.02

The first shipment of 960 magnets, enough for both of the 1st-article undulators, finally was delivered to the assembly vendors on the 3rd of January 2006. Later than planned.

We were told to expect a faster delivery rate after the new production line, installed to meet increased global demand for these high-quality magnets, began operation in December 2005.

Met with Shin-Etsu 17 January 2006 @ANL.

Marion M. White



Magnets received at Metalex 3rd January

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Our needs are met by Shin-Etsu’s Re-Commitment dated 19 Jan 2006:

Undulator# P3 Early Finish Shin-Etsu

1 2 3-Jan-06 Dec-05

3 4 1-Feb-06 Jan-065 6 1-Mar-06 Jan-06

7 8 9 1-Mar-06 Feb-0610 11 12 13 14 3-Apr-06 Feb-0615 16 17 18 19 1-May-06 Mar-06

20 21 22 1-Jun-06 Mar-0623 24 1-Jun-06 Apr-06

25 26 27 28 29 3-Jul-06 Apr-0630 1-Aug-06 Apr-06

31 32 33 1-Aug-06 May-0634 35 36 37 38 1-Sep-06 May-06

39 40 1-Sep-06 Jun-06

Marion M. White



LLP - Magnet Poles 1.04.03.03.03

19,200 vanadium permendur magnet poles. The material is forged into rectangular bars and annealed for ductility [www.vacuumschmelze.com], then sawed into slices, milled, ground, lapped to the precise dimensions, and finally annealed for best magnetic performance.

49% cobalt, 49% iron, 2% vanadium

Marion M. White



LLP Scope: Magnet Poles 1.04.03.03.03 (2)

Awarded to Hi-Tech Manufacturing, Schiller Park, IL [near O’Hare Airport].

Award value: about 1M$ Major simplification of the pole design, eliminating titanium wings, saved a lot.

Vendor has made similar items for APS.

Understands the job and has developed special tooling and processes for working with this tricky material.

Marion M. White



Magnet Poles – Progress @ Hi-Tech

Raw material is in house. 1st 1000 poles, enough for the 2 first-article undulators plus spares, were complete, inspected, and ready for delivery the week of November 7th;

Hi-Tech procured a new CMM to enable automatic inspection of the 19200 poles. Poles are ahead of the required schedule.

Marion M. White



Pole Mfg/Shipping SummaryPoles Sent To Metalex 50% of their needs

5000 Pieces L143-110105-03 (undulators 2, 4, 6,8,10,12,14,16,18,20)85 Pieces L143-110107-02

Completed For Hi-tech

1000 Pieces L143-110105-03 (undulators 1 and 3)10 Pieces L143-110107-02

Next Lot For Hi-tech (Ready By Mid-February)

4000 Pieces L143-110105-03 (undulators 5,7,9,11,13,15,17,19)75 Pieces L143-110107-02

Total Machined 13,000 Pieces

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Poles – example of inspection report

INSPECTION/ACCEPTANCE REPORT OF COMPONENTS FOR AS-BUILT DRAWINGS

VENDOR: Hi-Tech Manufacturing, Inc.

DRAWING #: L143-110105 P.0.#: 5A-05150

PART NAME: LCLS Magnet Structure Pole

SERIAL #: 01019

DATE: 11/03/05 10:52 AM

ACCEPTANCE CRITERIA

1 Visual inspection for shipping damage Accepted

CRITICAL DIMENSIONS (mm) #

Feature

Target & Tolerance

Measured Value

Result 1

Pole Height

48.000 -0.10 -.

47.995

Accepted

2

Pole Thickness

6.000 -0.050

5.979

Accepted

3

Base Flatness

0.010

0.001

Accepted

4

Back-to-Base Perpendicularity

0.025 -.

0.008

Accepted

5

Front-to-Back Parallelism

0.025

0.004

Accepted

6

Threaded Holes Location

3.000 ±0.050

3.000

Accepted

7

Temperature

20.0 ±2

19.800

Accepted

Procedure Number L1 43-00076 Revision; 0 Issue Date; April 14,2005

INSPECTOR:

FINAL CONCLUSION:

TEST EQUIPMENT USED:

QA SUPERVISOR:

ACCEPTED

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Magnet Poles – Mfg. Progress @ Hi-Tech

Staged for Assy.

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1st Article Undulator AssembliesPrototype undulator (now @SLAC) on a simple breadboard girder used to gain experience with CAM mover

control and monitoring @ANL.

Marion M. White



LLP – 1st-Article Undulator AssemblyFirst-article assembly awards were made to two vendors, with options for more pending 1st-article acceptance, available BA, and arrival of actual money at ANL.

Very favorable assembly costs; significant savings:Two 1st articles

Series of 38

The design, intellectual development, and prototyping were completely done by ANL, thus we could utilize precision machine shops instead of special-purpose magnet firms for the assembly. The budgeted amounts were based on past history with magnet specialists.

Intensive value engineering efforts and assembly planning contributed greatly to the savings.

Marion M. White



1st-Article Undulator Assembly - Two Awards:

Metalex - Blue Ash, OHMaking ½ of the strongbacksExcellent vendorSaves on shipping

Hi-Tech - Schiller Park, ILMaking all of the polesPerformed many jobs for APS in the pastSaves on shipping

Marion M. White



ES&H and Informational Visit

Representatives of both undulator assembly vendors visited the APS in October 2005 in order to see the prototype undulator before it was shipped to SLAC.

They gained valuable experience in safe handling of these extremely strong magnets, and were able to practice a little bit in preparation for assembly at their facilities.

Marion M. White



QA & Vendor Management

The APS undulator experts responsible for design, construction, assessment, and value engineering of the prototype undulator, are responsible to oversee the undulator magnet and support procurements.

Responsibility for vendor management, vendor oversight and performance, and undulator performance rests with ANL-APS.

Marion M. White



Vendor relations and management are critical.

If you start off right, chances for success are far better.

Even a superb vendor may need some prodding to get in tune with the program.

Incorporate QA from the start; pay attention to the details; work together with the vendors and keep procurement involved.

Marion M. White



Assembly Progress @ Hi-Tech

Hi-Tech has received all long lead items (LLP) required for its 1st article.

The assembly area as well as all required documentation deliverables, such as work plans, are ready.

Hi-Tech is 100% complete with non-LLP components and has started 1st-article undulator assembly.

Marion M. White



The Plan: Assembly – short base

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Assembly – short base with poles

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Assembly – short base - fully assembled with poles, magnets, and clamps

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Assembly – short base – fixture for precision positioning of the first poles

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Assembly – Use the transfer fixture for precision positioning of the next poles;

anchor with four poles

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Assembly – continue down the line

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Assembly – completed long base

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Insert Poles into Base; Joining Fixture @Hi-Tech

Poles are inserted into the long base using the precision fixture designed by ANL. The

four end poles are used as a locating reference for the next group.

The fixture that enables safe joining of the top and bottom is also ready.

Marion M. White



Poles assembled into bases, being

readied for insertion of

magnets and then assembly into the

strongback.

Hi-Tech 06 Feb 2006

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Magnets are

labeled and

arranged according

to our sorting

list; Red on top,

Green on the

bottom

Assembly Progress at Hi-Tech (07Feb06)

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Assembly Progress @ Metalex

All documentation received:Program PlanInspection and Test PlanningQuality Verification PlanProgram Schedule

Raw Materials are delivered.The assembly area dedicated to this project is prepared. All work benches, storage racks, overhead cranes, and special tools are ready. Parts are 100% ready.

Marion M. White



Assembly Progress @Metalex:

Short Bases

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Inspection of Short Base

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Assembly

Progress at

Metalex

Long Bases

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Clamps and Travelers

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Non-Magnetic Tools @ Metalex

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Assembly Area @Metalex – huge clean space – plenty of room for other things {ILC???}

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1st Article Assembly/Tuning ScheduleUN33_40060 AWARD: 1st Art Mag Assy - Hi-Tech 1 25-Oct-05 UN33_40100 Hi-Tech Procure - 1st Art Mag Assy Parts 42 10-Nov-05 19-Jan-06UN33_40110 RCV: Ti S/B Article 01, Blocks, Poles, Parts 0 03-Jan-06UN33_40120 Hi-Tech Fab/Assy-Mag Article 01 Assembly 42 20-Jan-06 20-Mar-06UN33_40122 Review Hi-Tech travelers/data 2 21-Mar-06 22-Mar-06 UN33_40124 Factory Acceptance Article 01 - Hi-Tech 2 23-Mar-06 24-Mar-06UN33_40128 Hi-Tech Undulator Article 01 Ship to ANL 1 28-Mar-06UN33_40140 RCV: From Hi-Tech - Magnet Assy #1 1 29-Mar-06UN33_00530 Mag Meas & Tune-Hi-Tech Article 01 21 30-Mar-06 27-Apr-06UN33_00550 ACCEPT: Hi-Tech Und Article 01 @ANL 5 28-Apr-06 04-May-06UN33_00554 ACCEPT: Hi-Tech Und Article 01 @SLAC 0 18-May-06

UN33_40150 AWARD: 1st Art Mag Assy - Metalex 1 26-Oct-05 UN33_40190 Metalex Procure - 1st Art Mag Assy Parts 42 15-Nov-05 24-Jan-06UN33_40200 RCV: Ti S/B Article 02, Blocks, Poles, Parts 0 03-Jan-06UN33_40210 Metalex Fab/Assy-Mag Article 02 Assembly 42 25-Jan-06 23-Mar-06UN33_40211 Review Metalex travelers/data 2 24-Mar-06 27-Mar-06UN33_40212 Factory Acceptance Article 02 - Metalex 2 28-Mar-06 29-Mar-06UN33_40214 Metalex Undulator Article 02 Ship to ANL 5 31-Mar-06 06-Apr-06UN33_40220 RCV: From Metalex - Magnet Assy #2 1 07-Apr-06UN33_00560 Mag Measure & Tune-Metalex Article 02 21 28-Apr-06 26-May-06UN33_00580 ACCEPT: Metalex Und Article 02 @ANL 5 30-May-06 05-Jun-06UN33_00620 ACCEPT: Metalex Und Article 02 @SLAC 0 19-Jun-06

Marion M. White



Single Undulator Test

Prototype Fixed SupportsPrototype Girder and Motion SystemPrototype or 1st-article UndulatorControls software and hardware for readout, monitoring, and motion control.Vacuum chamber prototype (solid) Quadrupole Ersatz BPM prototypeAll other components on the girder or in the break sections will be represented by actuals or Ersatz.

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Dummy Undulator on Prototype Girder @ANL

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Major things to be tested/verified

Does everything that is supposed to be on the girder actually fit together as planned?

Are the drawings final and verified?

Assembly procedures and sequences

Perform Component Calibration

Monitor and Assess Stability

Thermal and Vibrational Characteristics

Motion Control, Settability, Verification

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Example: Mechanical Verification ActivitiesCalibration of Cam Movers and Positioning Sensors (Collins)

Pure X-Translation TestsCyclic point-to-point repeatabilityCyclic repeatability about a center point position

Pure Y-Translation TestsCyclic point-to-point repeatabilityCyclic repeatability about a center point position

Pitch TestsUpstream Pitch cyclic point-to-point repeatabilityUpstream Pitch cyclic repeatability about a center point positionDownstream Pitch cyclic point-to-point repeatabilityDownstream Pitch cyclic repeatability about a center point position

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Mechanical Verification Activities (cont’d)Roll Tests

Inboard Roll cyclic point-to-point repeatabilityInboard Roll cyclic repeatability about a center point positionOutboard Roll cyclic point-to-point repeatabilityOutboard Roll cyclic repeatability about a center point position

Yaw TestsUpstream Yaw cyclic point-to-point repeatabilityUpstream Yaw cyclic repeatability about a center point positionDownstream Yaw cyclic point-to-point repeatabilityDownstream Yaw cyclic repeatability about a center point positionEvaluation of bearings and bearing surfaces after Yaw motions

IR Imaging: Influence of Motor HeatingCam Mover System Point-to-Point Accuracy Roll-Away System Testing

Cyclic point-to-point repeatability and accuracyCyclic repeatability and accuracy about a center point positionEvaluation of girder system Roll associated with the Roll-Away cycle

Undulator Segment Replacement to Verify Reproducibility

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SUT Schedule – LCLA BaselineActivity # Description days ES EF LS LF

33_00565 Develop Plan & Base Design for Single Und Test 31 01SEP05 * 14-Oct-05 26-Oct-05 9-Dec-05

33_00585 Prepare Area for Single Undulator Test 31 16-Sep-05 28-Oct-05 9-Nov-05 3-Jan-06

33_00595 Prepare Ctrls HW/SW for Single Und Test 42 16-Sep-05 14-Nov-05 16-Feb-06 14-Apr-06

33_00575 Assemble Test/Meas/Verification Stand 63 4-Nov-05 13-Feb-06 4-Jan-06 31-Mar-06

33_P0565 Pack & Ship Proto Undulator back to ANL 7 19-Jan-06 27-Jan-06 20-Mar-06 28-Mar-06

33_00665 Mount Proto Und on PR S/M 3 15-Feb-06 17-Feb-06 29-Mar-06 31-Mar-06

33_00566 AVAIL: Vacuum SUT Components 0 2-Mar-06 25-Nov-09

33_00567 AVAIL: Diagnostics SUT Components 0 10-Mar-06 25-Nov-09

33_00615 Assemble Module Components on Stand/Connect 10 13-Mar-06 24-Mar-06 3-Apr-06 14-Apr-06

33_00605 Carry out Short-Term Single Undulator Test 10 27-Mar-06 7-Apr-06 17-Apr-06 28-Apr-06

33_00324 Single Undulator Module Tested-Short Term 0 7-Apr-06 28-Apr-06

33_00635 Write Report: Short Term Test Results 10 10-Apr-06 21-Apr-06 14-Jun-06 27-Jun-06

33_40275 FDR - Supt/Mover System, Incl Controls Package 1 24-Apr-06 24-Apr-06 28-Jun-06 28-Jun-06

33_40305 AWARD: Support/Mover System 1st Articles 1 1-Jun-06 1-Jun-06 7-Aug-06 7-Aug-06

33_00545 Carry Out Longer Term Stability Single Und Test 42 10-Apr-06 7-Jun-06 22-Sep-09 18-Nov-09

33_00625 Single Undulator Module Tested - Long Term 0 7-Jun-06 18-Nov-09

33_40322 1st 2 Articles Support/Mover System recd. at ANL 0 30-Oct-06 15-Jan-07

34_00017 ACCEPT: 1st 2 Articles Support/Mover 0 30-Nov-06 25-Nov-09

Marion M. White



6-Month Look Ahead (from 8th Feb 2006)

Input detailed scheduling information from the LLP vendors into the schedule. OngoingAll LLPs available for 1st-article assemblies. DoneBoth 1st article undulators will be tuned @ANL.Undulator assembly vendors will be working on subsequent units, assuming funds. Support/mover and fixed support prototypes will be tested as part of the integrated undulator module test. Plans and preparations progressing well.Support/Mover and Fixed Support RFP’s out.Quadrupole magnet RFP out.

Marion M. White



We’re Having a Lot of Fun.

Marion M. White



Documents

Marion M. White Undulator Procurement and [email protected] 07-09 February 2006 DOE Mini-Review Undulator Magnets and Supports 20 February 2006