Undulator for the LCLS project from the prototype to the full scale manufacturing

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Undulator for the LCLS project from the
prototype to the full scale manufacturing

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OUTLINE

• Major Design features
• Latest Design Changes (Internal ANL Review - June
  18, 2004 )
• Long Lead Items
• Manufacturing Approach

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PARTIAL LIST of LCLS UNDULATOR REVIEW

2003 Lehman Review (May 21-23, 2003) -
Rockville, MD LCLS Undulator Parameter Workshop
- ANL - October 24, 2003 Review of the LCLC
Undulator - ANL - November 14, 2003 LCLS
Undulator Diagnostics and Commissioning Workshop
- UCLA - January 19-20, 2004 LCLS Undulator
System Review - ANL - March 3-4, 2004 Internal
ANL Review - June 18, 2004 External Independent
Review - SLAC - June 7-11, 2004 LCLS Undulator
Physics and Engineering Meeting - ANL - June
28-29, 2004 LCLS Undulator Meeting - ANL - July
23, 2004 Lehman Review at SLAC - August 10-12,
2004
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LCLS general view

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LCLS prototype undulator on the magnet measuring
stand
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LCLS Prototype Undulator (major design features )

1.Titanium housing made of forged 12 bar. 2.
Base of the magnet structure sections made of
aluminum alloy to partially compensate the
changes in the magnetization of the permanent
magnets with temperature. 3. Only one clamp
for each magnet is made of bronze. 4.
Incremental shims or might be used for the
undulator gap adjustment. 5. Out-bond area is
completely open for the side shims to tune the
field strength along the undulator. 6. Side
shims have four bars made of low carbon steel.
Each bar can be individually adjusted and
locked in place. 7. Five cam-shaft movers are
used for alignment of the undulator as a whole.
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LCLS Undulator Latest Design Changes

1. Canted undulator design (wedged shims)
proposed by Joachim Pflueger 2. Housing has
provision for magnetic needles and alignment
targets. 2. Simple pole design with two clamping
screws from the bottom. 3. Outside fixture
for the pole installation. 4. New side shim
design to decrease fringed field. 5. New
cam-shaft mover deisgn. 6. Magnet structure
base made as a single block (three parts before)
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LCLS undulator with wedged shims (canted)
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LCLS prototype undulator magnetic structure with
two pole clamps
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LCLS magnetic structure (old and new)
Implementation of the new design can save about
20K - 25K per undulator
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LCLS magnetic structure base new design
Implementation of this new design can save about
4K - 5K per undulator
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LCLS magnetic structure with a single unit base
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LCLS undulator pole assembly fixture
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Fixture for the Magnet Structure Assembly


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LCLS Prototype Undulator Titanium Housing

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LCLS Prototype Undulator magnetic needle test
set-up

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LCLS Undulator Housing Design Changes

Manufacturing simplification 1. Counterbore
clamping holes instead of counterbore groves. 2.
No provisions for phase shifters. 3. Central
grove for vacuum chamber location is removed. 4.
More simple provisions for the support pads.
Improvements for more precise alignment 1.
Housing has provision for magnetic needles on
both ends. 2. Housing has provisions for four
sets of alignment targets.
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LCLS Undulator Pole

Material VACOFLUX 50
(vanadium permendure) Quantity PER
UNDULATOR - 450 TOTAL
- 19200 TOTAL WEIGHT
5300 lbs
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LCLS Undulator Magnet

Material N39UH (Nd-Fe-B type
magnet ) Quantity PER UNDULATOR - 450
TOTAL -
19200 TOTAL WEIGHT 10900 lbs
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Manufacturing approach

• Design of the undulator itself is ready for
  manufacturing,
• Design of the undulator support cradle and all
  associated motions is 2005 year task.
  Nevertheless we cant see its impact on housing
  design. Some minor changes in the support area
  location can be easily corrected during the
  manufacturing we have time
• It is not necessary to work with only companies,
  who have undulator experience, our choice of
  vendors is quite wide
• We are going to teach and train selected vendor
  (vendors) how to assemble magnetic structure of
  LCLS undulator and how to put it inside housing.
  Detailed procedure is written and necessary
  fixtures are designed.

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Conclusion

• Prototype of the LCLS undulator was successfully
  designed,
• manufactured, tuned, and tested
• Multiple changes in the design of the prototype
  were
• implemented, tested in the preparation for
  the full scale
• production, and approved by internal
  design review
• Forty undulators will be manufactured in the
  next three years
• Procurement package for the long lead items
  (strong back,
• magnets and poles) is 98 ready
• We would like to have one LCLS undulator each
  two weeks.