Midterm Review 28-29/05/2015 Iordan Doytchinov ESR3.1, WP3 1

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Midterm Review 28-29/05/2015

Iordan DoytchinovESR3.1, WP3

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ESR3.1, WP3 /

Contract start date: 3rd March 2014

PACMAN subject: Ultra-precise quadrupole magnet assembly and testing. Integration of an alignment test-bed towards an industrial production

PhD title: Measurement uncertainty budget for future particle accelerators alignment bench

PhD Institution: Cranfield University

Secondment: DMP Spain (3M)

Iordan DOYTCHINOV, ESR3.1PACMAN Mid-term review 28-29/05/2015

CERN Supervisor Michele Modena

Academic supervisors Dr. Paul Comley, Prof. Paul SHORE

Industry supervisor Jorge Presa

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Background /

Test automation - 1 year

Vehicle Dynamics/ Performance - 3 months

Omron ltd Barcelona:Real-Time robot dynamics simulation (Master THESIS)UAV Performance Estimation

/system Integration

I come from here - Sofia - BULGARIA

Beside Engineering…


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PhD thesis /

Title: Measurement uncertainty budget for future particle accelerators alignment bench

Start date: 05.2014

Status: 1st year critical (GO/NO-GO) review passed

Note: Precision engineering training done at the university.


Project /

Place in PACMAN


Ultra-precise quadrupole magnets assembly and testing

Uncertainty budget for PACMAN and thus:

• Work contributed to PhD hypothesis formulation but not selected as one.

• research plan reformulated to follow closely PhD hypothesis

Bench System Integration – evaluation of system requirements and bottleneck problems

A) Defining its measurement capability.

B) Development of calibration and error compensation procedures for the system.

C) Proving if the concept can be scaled up for mass production.

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Project /

Objectives


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I) Define error sources contributing to the measurement uncertainty (current work)

JCGM 100:2008

P.R. Guimarães Couto1 et all (2013)

II) Allocate the level of measurement uncertainty for each critical error source

III) Construction of final integrated system uncertainty budget.

Prove or disprove if targeted measurement uncertainty is achievable:• 7 µm (BPM axis)

• 11 µm (Magnet axis)

Future work

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Project/

BPM

State of art

predicted expected error budget for this type of measurement.

Fig 22: Stretched wire setup measuring quadruple magnet [23]

Wire stretching bed by 2x spheres

Wire stretching bed by 2x spheres

> 20µm @ U(68%)

𝑈𝑝𝑟𝑒

−𝑎𝑙𝑖𝑔𝑛𝑚

𝑒𝑛𝑡

𝑈=√∑ 𝜎 2


State of the art

Project/

Iordan DOYTCHINOV, ESR3.1PACMAN Mid-term review 28-29/05/2015 8

Magnetic axis definition

Wire axis non- contact definition

within CMM

Tactile datum measurement

No in-depth uncertainty analysisNo common terminology or method applied Integrated uncertainty budget does not exist

GAP OF KNOWLEDGE:

Wire

Sensor

𝑼 𝟐

BPM axis definition

Research Gap

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Project /

Method followed


II) Literature review

I) QFD analysis, CAD studies , communication with sub system owners (PACMAN students)- System integration, definition of error sources

𝐔𝐩Measurement

ProcessUncertainty

budget

Changeassumptions

Task

- Standards (GUM, ISO)- Error budgets on complex

systems

III) Experiments design

- Evaluation of magnitude, sensitivity and correlation of uncertainty contributors in 4x work packages

Measurements

Electromagnetic

Task Specific Uncertainties

Sub System Uncertainties

Task specific uncertainties

BPM RF Axis Measurement

Magnetic Axis Measurement

Measurements

Electromagnetic





Magnetic Axis MeasurementMagnetic axis

measurement package

Measurements

Electromagnetic


Task specific uncertaintiesSub System Uncertainties




Electromagnetic

Thermal Issues BPM

Geometrical Issues

Vibration Issues

Measurements

Electromagnetic






Electromagnetic

Thermal Issues BPM

Geometrical Issues

Vibration Issues

BPM electric axis measurement

package

Measurements

Electromagnetic




Wire Location Measurement

Measurements

Electromagnetic




Wire Location MeasurementWire axis location

measurement package

Measurements

Electromagnetic




Global Zero Datum measurment - CMM Measurements of Sphere fiducials


Measurements

Electromagnetic






CMM task specific measurement uncertainty

evaluation package𝑼 𝟏

𝑼 𝟐

𝑼 𝟑𝑼 𝟒

Project /

Tasks description


9 months GO/ NO-GO 30th of April

DMP secondment 06.2015 – 09.2015

Magnetic axis definition uncertainty budget

evaluation02.2016

Zero datum uncertainty budget

evaluation11.2015

Electric axis definition

uncertainty budget evaluation

05.2016

Non-contact uncertainty budget

evaluation07.2016

2nd Year GO/NO-GO 04.2016

PACMAN integrated system U evaluation package

11.2016

Thesis preparation 03.2017

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Results


Assembly not trivial – errors correlate: Magnetic axis measurement to be included in the magnet assembly loop?

Practical assembly studies of quadruple magnet investigating existing methods

Literature review on the subject Assembly trials completed:Results:

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Relationship Matrix

Quality Function Deployment initial analysis done:

Results


Project /

Metrology loop interferenceNo access for non-contact sensor A) Re-design

B) Change of strategy

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Uncertainty analysis

Results


MeasurementsUncertainty Components

Electromagnetic




Vibration Issues


Thermal Issues

Geometrical issues

Vibration Issues


Sub-Systems Uncertainties



Electromagnetic

Thermal Issues BPM

Geometrical Issues

Vibration Issues



Thermal Issues

Vibration Issues

Geometrical Issues

Electromagnetic

Electromagnetic

Thermal Issues

Geometrical issues Quantify ΔT for current thermal control state of art

How ΔT of magnet propagates to magnetic axis

measurement?Udt= ΔT x α x L?

𝑼𝒎𝒂𝒈𝒏𝒆𝒕𝒊𝒄

𝑼 𝒆𝒍𝒆𝒄𝒕𝒓𝒊𝒄

Magnetic axis measurement

BPM electric axis

measurement

Wire axis location measurement

Zero datum measurement

(CMM)

MeasurementsUncertainty Components

Uncertainty Components Detail

Optical sensor measurment uncertaintyTension extrapolation error (wire sag correction)

Wire typeElectromagnetic External Electromagnetic Influence

Magnet HeatingEnviroment

Wire stretcher actuators and electronics thermal influence

Magnet cooling vibration influence @ Wire stretcher and Manget

Coultural noise through MBQ fraimeResolution of wire positioning in space

Perpendiculiarity of movement of axis stagesLocation magnet centre VS wire centre

Task Specific UncertaintiesTwo measurments to determine axis required

Other to be determined

Sub-Systems Uncertainties


Thermal Issues

Vibration Issues

Geometrical Issues

ΔT ?𝑈 𝑥

Time

T

ΔT

dt

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Training


Secondment in DMP – Spain(06.2015-10.2015):

“Analysis of error budget and uncertainties of robotic mechanisms for measuring the spine movement during transpedicular approach surgery” Opportunity to practice kinematics mechanism error

propagation budgeting Opportunity to spent time in precision engineering company:

Introduced to internal standards and procedures on metrology and manufacturing.

Precision engineering training in Cranfield University 1 week (11 principles of precision design)

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Training /


Training (at CERN) on metrology and alignment- 3 day ISO GD&T course- 2 day general metrology- 1 week spent as apprentice in metrology

laboratory

Training (at CERN) on CATIA software – 2 weeks

Training (at CERN) on ANSYS software – 1 week

“Teambuilding” development course (1day)

Presentation making development course (3days)

Language course – basic level French

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Conferences & workshop:

Participation to EUSPEN 2014 Meeting on Thermal Issues

Participation and presenting in PACMAN workshop

CONTROL fair Stuttgart (discussed and shared PACMAN project with industry)Outreach &Dissemination /


Other: CERN guides training

At CERN

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Networking Opportunities /


Visit at KOTEM technologies in Budapest

Organised a visit and presentations of KOTEM and SIGMETRIX tolerance analysis software companies at CERN

CONTROL fair Stuttgart

PACMAN workshop

Discussions and online meetings with PhD students from Brazilian Synchrotron Light Source working on similar project

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Impact


Contribution to DMP research project error and uncertainty analysis for medical purposes (DMP)

Personal

Dissolution my borders

Made me believe

Professional

Contribution to system integration required for PACMAN project (CERN)

Contribution to state of art in uncertainty analysis in accelerator components pre-alignment (CERN)

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Midterm Review 28-29/05/2015

Thank you for your attention

“If you grasp the principles – myths fall & Ideas take-off” David Lentink

(TUDELFT) TED Conference Amsterdam

خليفة “) (“Khalifa Tower" ,برج– Dubai 2010

Babylon tower by Tobias Verhaecht (1561 – 1631)

Documents

Midterm Review 28-29/05/2015 Iordan Doytchinov ESR3.1, WP3 1