Progress on the Undulator Module System Test

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Progress on the Undulator Module System Test

• Marion M. White
• ANL-ASD-LCLS

2
Outline

• Test Scope and Deliverables
• Components
• Setup
• Progress
• Documentation, Requirements
• Continued Plans
• Schedule
• Summary

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

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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.

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Requirements

• 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

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Goals to Demonstrate

• Precision and repeatability of the cam-shaft
  system vertically and transversely, measured _at_
  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

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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 _at_ 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.

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Prototype undulator at ANL on breadboard
support/mover system
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Prototype Girder

• Two rigid steel prototype girders are now being
  fabricated at Lynn Machine, near OHare 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.

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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,

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Single CAM-shaft Mover

• New gear box with ratio 2501 is installed.
• Calculations show this ratio is enough to hold
  the undulator and girder in place without a
  brake.
• Less complexity.

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Double CAM-shaft Mover
The same changes were implemented in this unit as
in the single cam-shaft.
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Double CAM-shaft Mover (detail)
Hardness of the rings on the ball-bearings was
increased from 30-34 Rc to 50-55 Rc
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Single CAM-shaft Mover working w/ V pad
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.
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Single CAM-shaft Mover
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Parts in-house by end of November

• Undulator substitute unit
• expected 11/15
• New cam-shaft movers with new gear boxes
• expected 11/25
• Modified transverse stages with 4 travel
• in-house
• Motors (in-house) and 90? gear boxes for stages
• expected 10/31
• Transition plates, wedges and supporting parts
• expected 11/25

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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
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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
Target Repeatability lt /- 7.0 µm
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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.

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Fixed Support Design

• 18 Support Tube
• 1½ Support Plates
• Sand Filled
• 3 Wool Fiber Insulation
• 1½ Anchor Bolts

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Installation Alignment

• Design 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)
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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 pumps
• Cabling, supports, and junctions
• Magnet water piping
• WPM, 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

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layout in short breakcartoon stages and stands
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Earthquake bracing
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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.

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Schedule
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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.

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