Single Undulator Test and Integration

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Single Undulator Test and Integration

• Geoff Pile

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Overview of results from the Single Undulator
Tests
Information taken from various presentations of
An Internal SUT review Thanks to the SUT
construction team.
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Our First Renderings of the SUT
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Original Goals of the Single Undulator Test

• Provide critical input to the S/M system design
  reviews.
• Help to determine whether the support/mover
  system design is ready for final production.
• Measurement of girder and rollaway motions
• Determine precision and reproducibility of
  motions, including start and stop. Check for
  interference
• Measure vibration damping or (hopefully not)
  amplification.
• Measure position stability and temperature
  dependence of components and subcomponents.
• Practice Undulator replacement technique on SUT
  translation stages
• Enhance the Final Integrated Design for
  production

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The actual SUT set up in MM1
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The Test Plan Included

• Support Mover System Testing
• Control System Testing
• Mock Vacuum System Testing
• Diagnostic Quad System Testing
• Kinematic Undulator Replacement
• Alignment Checks/Tests

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Support/Mover System Testing
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Support/Mover System Testing
Salient Support/Mover System Physics Requirements

• Quadrupole Motion Positioning Repeatability 7
  µm
• Quad. Center Stability after Fiducialization 1
  0 µm
• Short-Term (1 h) BPM and Quad Stability 2 µm
• Long-Term (24 h) BPM and Quad Stability 5 µm
• Horiz. Segment Pos. Repeatability in Roll-Away
  Cycle 10 µm
• Vert. Segment Pos. Repeatability in Roll-Away
  Cycle 5 µm
• Quad Transverse Position Change in Roll-Out
  Condition 25 µm
• Quad Position Reproducibility after Roll-Away
  Cycle 2 µm
• BPM Transverse Position Change in Roll-Out
  Condition 25 µm
• BPM Position Reproducibility after Roll-Away
  Cycle 2 µm
• Note The MM1 Facility Lacks Adequate
  Temperature Control

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Support Mover System Testing

• SUT Keyence CCD Laser Displacement Sensor Layout

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Support/Mover System Testing
Sensor Name Measuring Range Resolution Sensor Measurement Function
XUpstream 5 mm 0.05 µm Horizontal Upstream Beam Center Position BFW Manual Stage
YUpstream 5 mm 0.05 µm Vertical Upstream Beam Center Position BFW Manual Stage
XDownstream 5 mm 0.05 µm Horizontal Downstream Beam Center Position BPM Manual Stage
YDownstream 5 mm 0.05 µm Vertical Downstream Beam Center Position BPM Manual Stage
YMidstream 5 mm 0.05 µm Middle Edge of Girder at Beam Height for System Roll
XQuad 5 mm 0.05 µm Horizontal Position at Beam Height for Quad Manual Stage
YQuad 5 mm 0.05 µm Vertical Position at Beam Height for Quad Manual Stage
XUpstream Translation 40 mm 0.5 µm Upstream Undulator Segment Position for Roll-Away System
XDownstream Translation 40 mm 0.5 µm Downstream Undulator Segment Position for Roll-Away System
YFloor 1 -250 mm/500 mm 2.0 µm Upstream Outboard Vertical Position of Girder Relative to Floor
YFloor 2 -250 mm/500 mm 2.0 µm Downstream Outboard Vertical Position of Girder Relative to Floor
YFloor 3 -250 mm/500 mm 2.0 µm Inboard Middle Edge Vertical Position of Girder Relative to Floor
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Support/Mover System Testing
XDownstream Translation
XQuad
YQuad
XDownstream
YDownstream
YFloor 2
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Support/Mover Roll out System Testing
LCLS Undulator Roll out Requirements 8.12
Wire center ? ?40 mm (not in PRD) in ID roll-out
condition.
Girder Upstream
BPM/Quad center ? ?25 mm in ID roll-out condition.
Girder Downstream
Total weight 4060 lbs. ID weight 2140 lbs. ID
motion range 80 mm. Load change max /-350
lbs.
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Support/Mover Roll out System Testing
Test Results with the Original System
Wire center X16 mm, Y37 mm in ID roll-out
condition.
Girder Upstream
CAM 5
CAM 4
BPM/Quad center X103 mm, Y10 mm in ID roll-out
condition.
Girder Downstream
CAM 2
CAM 3
CAM 1
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Modified Downstream Wedge Blocks both from 45 to
25.6 and 43
Test Results with the Cam System swapped end to
end with 1 modified wedge block (overcorrected
negative)
Wire center X66 mm, Y22 mm in ID roll-out
condition.
BPM/Quad center X-23 mm, Y-12 mm in ID
roll-out condition.
Fully optimized system meets spec
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Modified Downstream Outboard Wedge Block from 45
to 25.6/41.9
Readings from the Keyence Sensors During a Full
Cycle of the 80 mm. Roll-Out and Roll-In Cycles
(2 sets of data/round trip)
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Support/Mover System Testing
Conclusions

• The Cam-Mover System Tests Resolution and
  Backlash Results are Excellent for all Degrees
  of Motion Freedom and Well Within Specifications
• With Feedback Added, The Cam-Mover System is
  Able to Achieve Any Move Within the Command
  Space to Within 2 µm with No More Than One
  Iteration
• The Roll-Away System Backlash and Resolution
  Results are Excellent and Well Within
  Specifications
• All Motions for Both Motion Systems are
  Extremely Repeatable
• With the New Gearbox Design Motor Heating
  Effects are Non-Existent
• Engineering Solutions to Make the System Even
  Better are Underway

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Control System Testing
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Control System Testing

• The electronic rack for the SUT incorporates
  most of the hardware control systems for the
  undulator components.
• It requires 120 volts and an Ethernet
  connection.
• The real rack will conform to SLAC rack systems
  earthquake specs

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Control System Testing
The SUT control system is based on Lab View. Here
is the main operating screen The Epics control
system will be utilized on the Long Term
Tests The engineering operating screens will be
designed and integrated with SLAC (Stein, Xu and
Dalesio)
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Control System Testing
Wiring on SUT was point to point traditionally
wired. Prototype cableway for control and
monitoring system has been developed. Locates
under Undulator Girder. Final design is being
reviewed now. Vendor-made with standardized
connectors. gt30 matching cables will be
manufactured to interconnect with hardware e.g.
motors, thermocouples, potentiometers, BFW, etc.
etc. 33 cableways needed x 30 cables each
1000 cables. Installation will be easy
commissioning will be even easier due to ISO 9000
build and testing.
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Control System Testing
Special test equipment was constructed to aid
with control system testing. Keyence Inclinometer
Thermal Vibration
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Mock Vacuum System Testing
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Vacuum Chamber Adjustment Mechanism
Compound screws - 5/8-18 screw - 7/16-20
screw
Z-adjustment 5/16-18 screws
X-adjustment 5/16-18 screw

• Y Vertical Adjustment - Compound screws
• Total 26 threaded holes
• 14 screws for vertical adjustment
• Other 12 threaded holes for lifting / adjustments
  
• X-Z Horizontal Adjustments Cap screws

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Compound Screw Tests

• Performed the compound screw adjustment tests (2,
  6, 14 screws).
• Adjustment test showed that it is possible to get
  fine adjustment, but it was cumbersome to align.
  It also showed that the locking nut makes the
  process difficult, but that it is sufficient to
  use. It works in both directions to adjust the
  vertical height of the mockup.
• A laboratory test is set-up with a single
  compound screw and with the proper selection of
  materials, EP SST and MoS2 lub, also brass. The
  backlash is small enough not to hinder micron
  level adjustments.
• Finally, we chose 5/8-18 Brass and 7/16-20 SST
  compound screws to prevent galling

Six Compound Screws Set-up (42 long)
Fourteen Compound Screws Full Chamber Mock-up
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Lifting tests

• Lifting spreader was designed to help lifting up
  the vacuum chamber assembly and lifting plan was
  documented.
• Lifting spreader was certified from the ESH
  inspector after QA inspection and static load
  test (500 lb).
• No hazards found during the chamber installation.

Figure 7. Figure
8. Figure 9.
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Breakdown of the spacing

between the undulator and the vacuum chamber
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Mock Vacuum System Testing Vacuum Chamber
alignment
mm
Vertical Adjustment Screws (14)
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Diagnostic Systems Testing

• Ersatz Quad, Beam Position Monitor and Beam
  Finder Wire alignment and positioning was
  successful.
• The Support and translation systems for these
  items have been studied and the designs are
  acceptable. All positioning and roll out specs
  have been met.

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Assemblies and Cross Sections

• Assembly

Bellows Flange
BFW Flange Seal
Locating Pins
Beam Tube Spider
Shielding Cut-out
Vacuum Flange
Vacuum Chamber Flange
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Diagnostic Systems Testing

• Beam Finder Wire
• As part of the SUT, vibration tests were run on a
  BFW system mock-up. The mock-up was sufficiently
  stable.
• As part of the SUT, the mounting system for the
  BFW was tested for positioning accuracy. The
  mount system can locate the Chamber to within /-
  10 µm in X and Y.

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Kinematic Undulator Replacement
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SUT Undulator Segment Replacement Testing
Background

• The Magnetic Axis of each Undulator Segment is
  Fiducialized to a Fixed Horizontal and Vertical
  Dimension using Shim Plates Underneath and on
  the Ends of the Undulator Support Plates in
  order to make all Undulator Segments Identical
  and Interchangeable.
• When Referenced to the Undulator Alignment Pins
  on the Stage Transition Plates, Undulator
  Segments can be Interchanged Without the need for
  Realignment.
• The Total Tolerance Budget Mandates that this
  Process Must be Repeatable to within 180 µm rms
  Horizontally and 70 µm rms Vertically. In
  Reality, the Process Needs to be Repeatable to
  Within a Percentage of this Tolerance to Allow
  for Additional Tolerance Stack Up Elsewhere.

Purpose

• Using only One Undulator Segment, Determine the
  Positioning Repeatability at Both End of the
  Undulator after Removal and Reinstallation.

From Robert Rulands 7/7/05 Presentation
Alignment Considerations
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SUT Undulator Segment Replacement Testing
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SUT Undulator Segment Replacement Testing
Lifting/Positioning Fixture
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SUT Undulator Segment Replacement Testing
August 2006 Testing Method

• Dual Sets of Four Keyence Sensors were used to
  Measure the X and Y Displacement at Both Ends of
  the Undulators Relative to the Girder. The
  Dummy Undulator and the Actual Undulator had
  their Own Dedicated Set of Keyence Sensors so
  that Zero Positions Could be Maintained when
  Switching Between the 2 Undulators
• Positions were Zeroed at the Undulator Zero
  Position. The Undulator was then Retracted to
  the 80 mm Position, Unbolted and Removed from the
  Stages using our Lifting and Positioning
  Fixtures.
• The Weight of the Undulator was Removed from the
  Girder using a Forklift.
• The Undulator was then Lowered to the Lifting
  Fixtures and Brought back Down onto the Stages.
• Bolts were Retightened using a Torque Wrench and
  then the Undulator was Returned to the Home
  Zero Position. The Keyence Sensors were Read
  and Recorded at this Time and Compared with the
  Laser Tracker System Results.
• This Method was Repeated 4 Times for the Dummy
  Undulator and 3 Times for the Actual Undulator.

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SUT Undulator Segment Replacement Testing
Xupstream
Yupstream
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SUT Undulator Segment Replacement Testing
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SUT Undulator Segment Replacement Testing
Kinematic replacement of undulator Conclusions

• The Process of Replacing an Undulator Segment is
  Quick and Easy Using the Lifting and Positioning
  Fixtures.
• The Process is Very Accurate and Repeatable.
• The Worst Case Repeatability for Vertical
  Alignment is Less than 10 Microns.
• The Worst Case Repeatability for Horizontal
  Alignment is Less than 40 Microns.
• The Laser Tracker Network Established around the
  SUT Provides Excellent Results that are in Good
  Agreement with the Keyence Sensor Measurements.
• The Laser Tracker Network will be Used
  Throughout SUT Testing to Provide a Secondary
  Set of Measurements for Comparison to The Keyence
  Sensors and Positioning Potentiometers.

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Support/Mover System Testing
Survey Alignment Support

• LEICA LTD 500 Laser Tracker System Used for
  System Alignment
• Local Reference Network Established with 9 Fixed
  Monuments Distributed Around the SUT at Various
  Elevations
• Largest Measured Distance was around 3.5 m and
  Thus the Measurement Accuracy was On the Order
  of Tens of Microns
• Mini-Monuments Used on the Girder, Undulator,
  and Fixed Bases for Alignment of these
  Components. Tracker Also Used to Set Translation
  Stage Alignment Pins
• Optical Level System Used to Align Vacuum
  Chamber
• Taylor-Hobson Talyvel 4 Used for System
  Distortion Measurements During the Roll-Away
  Cycle

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Final Alignment Summary
Support/Mover System Testing

• Support Stands were set in elevation, pitch and
  roll to 0.10 mm.
• The Interface Plates fell within 0.05 mm in all
  areas.
• Final alignment of the girder was achieved to
  within 10 µm in pitch, roll and elevation, yaw
  and x were within 40 µm.
• 80mm roll out tests were successfully tracked
  with the laser and compared very well against
  Keyence sensor results.

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So how did we do? - We learned a lot!

• Support Mover (inc. fixed supports) System
  Testing
• Initial tests were very successful Most
  of the requirements have been achieved and we
  learned what we had to change to meet or exceed
  the remaining requirements. Final designs will
  incorporate all of the experience we gained and
  changes required to meet these specs.
• Changes include modifications to the fixed
  supports, girder, translation stages, wedge
  blocks, cam movers and gearboxes.
• Undulator Roll Out
• Testing and rapid wedge block development has
  resolved very challenging specs that could have
  been a significant problem.
• Kinematic Undulator Replacement
• Initial tests (dummy only) were very successful
  We appeared to be well in spec but had to
  complete the tests with the First Article 1 and
  the dummy undulator. Final numbers are well in
  spec. Making all undulator equal in production
  will be a relatively easy process.
• Diagnostic System Testing
• Initial installation, alignment and integration
  of ersatz BPM and BFW look very good.
• Setting the stages (settability) to a go to
  position is very good.

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Final Design enhancements

• Larger clearance holes on the base plate.
• More anchor points around the base plate.
• Illustration of possible mounting points. (8)
  total points will be used in the final design.
• Larger diameter support structure.
• Standard parts will be investigated for this
  improvement.
• Larger threaded rods between the base top plate
  and the interface plate.
• Thinner grout with an improved floor mounting
  method.

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Design Summary
Earthquake Restraints
Cam Mounting Pads
1 ½ Interface Plate
1 ½ Top Plate
1½ Support Rod
3 Fiber Wool Insulation (Not Shown)
1- 8 Base Leveling / Anchor Bolts
1 ½ Bottom Plate
Support Pads
Expanding Grout (Not Shown)
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• Integration

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Integration

• Rodd Pope is talking about schedule and assembly
  integration at SLAC. Heres a different look at
  an example of some of our project integration.
• in?te?grate '?n t??gre?t

verb (used with object)
1 to make up, combine, or complete to produce a whole or a larger unit, as parts do.
2 to bring together or incorporate (parts) into a whole.
We made up the following integration tool and are
currently developing it. It will be web
accessible by Lehman Review.
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Integration
We all need to ASK for information to integrate
efficiently. This is called the ASK
system. Assembly Sub-assembly Kit

• Example
• Select Support mover on this interactive web
  page.
• Support Mover box opens up main three areas
• 2. Select Fixed Support

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Integration
Fixed Support Assembly. wbs 1.04.03.08 B.O.M A.
S.K. S.O.W Installation info
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Integration
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Integration
Microsoft Access Links P3 Information PARIS
Procurement info Intralink Free form entry allows
input from QAR CAMs SLAC integration engineers.