Marion M. White Undulator System [email protected] 27 October 2005 - FAC LCLSLCLSLCLSLCLS Progress on the Undulator Module System Test Marion M

Marion M. White

Undulator System Tests [email protected]

27 October 2005 - FAC

LLCCLLSS

Progress on the Undulator Module

System Test

Marion M. White

ANL-ASD-LCLS

Marion M. White



LLCCLLSS

Outline

Test Scope and Deliverables Components

Setup

Progress

Documentation, Requirements

Continued Plans

Schedule

Summary

Marion M. White



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Test Scope

Resolve remaining design questions on the support/mover and fixed support systems; fill in details and make improvements as needed

Provide critical input to S/M system design reviews. Stability Repeatability Control and motionRobust

Are the support/mover and fixed support systems ready for production?

Marion M. White



LLCCLLSS

Deliverables

Measurement of girder and rollaway motions

Precision, reproducibility, and independence of motions, including start and stop

Check for interference

Calibration

Measurement of vibration damping.

Measurement of position stability and temperature dependence of components and subcomponents.

Marion M. White



LLCCLLSS• Quadrupole Motion Positioning Repeatability ±7 µm

• Short-Term (1 h) BPM / Quad Stability ±2 µm• Long-Term (24 h) BPM / Quad Stability ±5 µm

• Horiz. Segment Pos. Repeat. in Roll-Away Cycle ±10 µm• Vert. Segment Pos. Repeat. in Roll-Away Cycle ±5 µm

• Quad Transverse Position Change in Roll-Out ±25 µm• Quad Position Reproducibility after Roll-Away Cycle ±2 µm

• BPM Transverse Position Change in Roll-Out ±25 µm • BPM Position Reproducibility after Roll-Out Cycle ±2 µm

Requirements

Marion M. White



LLCCLLSSPrecision and repeatability of the cam-shaft system

vertically and transversely, measured @ undulator ends, for pitch and yaw motion as well.

Goal is ± 5µ specification ± 7µ;

Precision and repeatability of 80-mm transverse travel on the linear stages.

Goal is ± 10µ

Precision of the K-value adjustment using transverse linear stages.

Goal is ± 10µ

Short term stability (10 hours) of the girder and undulator.

Goal is ± 5µ; specification ± 5µ

Goals to Demonstrate

Marion M. White



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Components

Prototype undulator, or the substitute, or a 1st article if one is available and measured.

Prototype support/mover system: Girder, CAM movers, Rollaway system, controls software and hardware

Quadrupole Ersatz with fiducialization surfaces

BPM Ersatz with fiducialization surfaces

Vacuum Chamber Ersatz

WPM, HLS, BLM sensors or Ersatz

Prototype Fixed Support

Earthquake protection bracing – early prototype

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Preparation @ ANL

Tests are done in the APS Magnet Measurement Area, MM1

Temperature regulated

May need a plastic tent to improve thermal regulation

Clean area

Adequate space

Experienced People

Well-known floor and mechanically stable area

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A lot of work is done

A lot of work was already done using the breadboard girder, setting up the whole system, installing and learning to use the monitoring equipment, making improvements and design modifications, and writing control and monitoring software.

The results were surprisingly good, even for the rudimentary breadboard girder, so even better performance is expected in the real prototype.

Most designs are done, and most parts are on order or in-house for the test.

Marion M. White



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Prototype undulator at ANL on breadboard support/mover system

Marion M. White



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Prototype Girder

•Two rigid steel prototype girders are now being fabricated at Lynn Machine, near O’Hare airport in Chicago.

•One will be used for the integrated undulator test, and the other will be used for mechanical measurements without disturbing the undulator testing activities.

•The girders will be delivered to ANL by early November.

Marion M. White



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Improvements to the CAMs

Improvements were made to the CAMs as a result of information gained in the setup and learning phase.

Split bearing, hardness changed, spherical bearing, v-plate, more gear ratio, no brakes, …

Marion M. White



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•New gear box with ratio 250:1 is installed.

•Calculations show this ratio is enough to hold the undulator and girder in place without a brake.

•Less complexity.

Single CAM-shaft Mover

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The same changes were implemented in this unit as in the single cam-shaft.

Double CAM-shaft Mover

Marion M. White



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Hardness of the rings on the ball-bearings was increased from

30-34 Rc to

50-55 Rc

Double CAM-shaft Mover (detail)

Marion M. White



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The flat pad is replaced by one with a “V” shape - 16 angle.

A double bearing is installed instead of the single bearing

Its purpose is to replace sliding friction by rolling friction.

Single CAM-shaft Mover working w/ “V” pad

Marion M. White



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Single CAM-shaft Mover

Marion M. White



LLCCLLSSUndulator substitute unit

expected 11/15New cam-shaft movers with new gear boxes

expected 11/25Modified transverse stages with 4” travel

in-houseMotors (in-house) and 90 gear boxes for stages

expected 10/31Transition plates, wedges and supporting parts

expected 11/25

Parts in-house by end of November

Marion M. White



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Controls hardware & software

Position settability and monitoring

Verification of motion, repeatability

Verification of limits

Reproducibility and smoothness of start and stop

Temperature monitoring

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Controls/Monitoring Working

Marion M. White



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Case 1: X-Translation +/- 1.5 mm Cyclic Motion Repeatability

Location Laser Displacement Sensors

Linear Potentiometers

Upstream X ± 2.5 µm ± 1.5 µm

Upstream Y ± 1.0 µm ± 4.0 µm

Downstream X ± 2.0 µm ± 2.5 µm

Downstream Y ± 0.5 µm ± 4.0 µm

50

60

70

80

90

100

110

0 100 200 300 400 500 600 700 800

Laser Upstream X

Number of Cycles

X-Translation: +/- 1.5 mm Cyclic Motion Repeatability

Average Repeatability +/- 2.5 microns

Target Repeatability < +/- 7.0 µm

Marion M. White



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Fixed Support

ANL assumed the Fixed Support scope: a prototype will be designed, constructed, instrumented, and ready for evaluation as a part of this test.

The FDR will address the entire support/motion system, including the fixed supports.

Marion M. White



LLCCLLSS18” Support Tube

1½” Support Plates

Sand Filled

3” Wool Fiber Insulation

1½” Anchor Bolts

Fixed Support Design

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Installation & AlignmentDesign for fixed supports takes alignment and installation into account – integration of alignment philosophy with SLAC is ongoing.

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Module Layout for Integrated Test

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Designs are well underway: Undulator on the girder (left end)

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Designs: undulator on the girder (right end)

Marion M. White



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Use Ersatz Units as Needed

The quadrupole, BPM, and vacuum chamber are fiducialized Ersatz units with the right size and weight. Some real units are planned:

Pumping crosses and pumpsCabling, supports, and junctionsMagnet water pipingWPM, HLS, BLM sensors

Some kind of Earthquake bracing will be determined in collaboration with the SLAC safety committee, and will be incorporated; it may not be final

Marion M. White



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layout in short break;cartoon stages and stands

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Earthquake bracing

Marion M. White



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Schedule

Design/procuring vacuum/diagnostic components

Developing detailed plan and refining engineering specifications.

Controls HW/SW demonstrated; debug/improve

Prepare/fabricate test stand and components August thru November 2005; On track to have many of the components by December 2005.

Assemble early CY-06

Short term test March 2006; leads to FDR; with longer-term 2-month test continuing after that.

Marion M. White



LLCCLLSS

Schedule Description Early Start Early Finish

Develop Plan & Base Design for Single Und Test 31-Aug-05 13-Oct-05Prepare Area for Single Undulator Test 15-Sep-05 27-Oct-05Prepare Ctrls HW/SW for Single Und Test 15-Sep-05 11-Nov-05Assemble Test/Meas/Verification Stand 04-Nov-05 13-Feb-06Prep for FDR - Supt/Mover System, Incl Ctrls Pkg 07-Mar-06 13-Mar-06Prototype Supt/Mover System w/Final Rqmts 06-Jan-06 06-Mar-06Assy of Fixed Supports at Integrated System Tst 07-Feb-06 13-Feb-06Mount Proto Und on PR S/M 07-Mar-06 09-Mar-06Assemble Module Components on Stand/Connect 10-Mar-06 23-Mar-06Carry out Short-Term Single Undulator Test 24-Mar-06 06-Apr-06Write Report: Short Term Test Results 07-Apr-06 20-Apr-06FDR - Supt/Mover System, Incl Controls Package 21-Apr-06 21-Apr-06Release RFP - Support/Mover System 21-Apr-06Release RFP for Pillar/Plates/Insulation 08-May-06

Marion M. White



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Summary

An undulator module test will be carried out at ANL in Winter 05-06 using prototype and substitute components.

The test will provide critical data for the support/mover system final design review prior to production.

Much work was already done in Fall 05, leading to improvements in system design, choice of components, and control.

Many parts are either in-house or on order.

Controls and monitoring software was written and already demonstrated and debugged. Calibration in progress.

Remaining hardware is expected in time.

Marion M. White



LLCCLLSS

Documents

Marion M. White Undulator System [email protected] 27 October 2005 - FAC LCLSLCLSLCLSLCLS Progress on the Undulator Module System Test Marion M