Beam Finder Wire BFW Status Jim Bailey October
Beam Finder Wire (BFW) Status Jim Bailey October 25, 2006 Undulator Systems – BFW Diagnostics Jim Bailey jbailey@anl. gov
Introduction BFW Purpose Locate the center line of the Undulator relative to the electron beam BFW Function Located upstream of each Undulator Segment Fiducialized so that its horizontal and vertical wires have a fixed and known locations with respect to Undulator center line (girder axis) October 25, 2006 Undulator Systems – BFW Diagnostics Jim Bailey jbailey@anl. gov
Introduction Con’t Wires are brought into collision with the electron beam by movement of the Undulator Segment Amount of beam striking the wires are measured via beam induced current in the wires Or by detection of scattered particles down stream Relative position of beam and undulator is determined by the above measurements Wires are removed from the beam path October 25, 2006 Undulator Systems – BFW Diagnostics Jim Bailey jbailey@anl. gov
BFW In Situ- Short Break Undulator BFW Undulator Beam Girder October 25, 2006 Undulator Systems – BFW Diagnostics Jim Bailey jbailey@anl. gov
Physics Related Engineering Requirements One Vertical and One Horizontal Wire Independent Signal from Each Wire 0. 030 – 0. 040 mm Diameter Carbon Fiber Remotely Removal from Beam Path Hardware Clearance Radius at Target >2 mm October 25, 2006 Undulator Systems – BFW Diagnostics Jim Bailey jbailey@anl. gov
Physics Related Engr. Req’ts. (Cont’d) Wire Positioning Perpendicularity 10 mrad Roll, Pitch, Yaw 10 mrad (10 mrad: 0. 01”/1”) Y-Wire Reproducibility 30µm X-Wire Reproducibility 80µm Measured Position of Wires Relative to External Fiducial to be within 30µm Provide Adjustment per Above Location Tolerance (Implied) +/- 0. 050 mm October 25, 2006 Undulator Systems – BFW Diagnostics Jim Bailey jbailey@anl. gov
BFW Assembly Mounted on Adjustable Support Electrical Connectors for Wire Signals Potentiometer Compression Spring Positioner Pneumatic Solenoid Valve Air Supply Shut Off Valve Precision Screw Card Position Monitor (Limit switches) Frame Housing Alignment Fiducials Pneumatic Cylinder Vacuum Chamber Connection Flange (NW-50 Ce. Fix w/Clamp) Beam Port October 25, 2006 Undulator Systems – BFW Diagnostics Vacuum Pump Connector (2. 75” Conflat Flange) Adjustable Mounting Support Jim Bailey jbailey@anl. gov
BFW Assembly (Body Sectioned) Wire Card Down in Inactive Mode Electrical Connectors (Down Position) Potentiometer (Out Position) Internal Return Spring (Expanded Position) Internal Kinematic Stop Plates (Open Position) Bellows Seal (Compressed Position) BEAM October 25, 2006 Undulator Systems – BFW Diagnostics Pneumatic Solenoid Valve (Cylinder Vent Position) Lower Limit Switch (Actuated Position) Wire card (Down Position) Jim Bailey jbailey@anl. gov
BFW Assembly (Body Sectioned) Wire Card Up in Active Mode Electrical Connectors (Up Position) Potentiometer (In Position) Internal Return Spring (Compressed Position) Internal Kinematic Stop Plates (Closed Position) Pneumatic Solenoid Valve (Cylinder Pressurized Position) Bellows Seal (Expanded Position) Upper Limit Switch (Actuated Position) BEAM October 25, 2006 Undulator Systems – BFW Diagnostics Wire card (Up Position) Jim Bailey jbailey@anl. gov
Moving Slide Assembly (Solid Body) Electrical Connector and Feedthrough Secured to Slide Rod Top of Return Spring Fixed to Frame Slide Block Secured to Slide Rod Card Mount Block Secured to Slide Rod October 25, 2006 Undulator Systems – BFW Diagnostics Kinematic Stop Top Plate Fixed to Frame (Adjustable using precision Screws) Kinematic Stop Bottom Plate Secured to Slide Block Cylinder Bore Fixed to Frame Jim Bailey jbailey@anl. gov
How Kinematic Plate Adjustment Works Precision Screws Spring Loaded Positioner Frame October 25, 2006 Undulator Systems – BFW Diagnostics Locking Screw with Lock Washer Precision Screw Clearance between slide rod and frame Top Kinematic Plate attached to Frame Jim Bailey jbailey@anl. gov
Wire Card in Situ (Active Mode) Slide Rod* Card Mounting Block Ceramic Insulating Beads (TYP)* Locking Collar Note: * Signal Conductor and Insulating beads pass through center hole in the Slide Rod Vacuum Seal Gasket Mounting Screw (TYP) Winding Pin (TYP) Signal Conductor (TYP)* Wire Tensioner (TYP) Horizontal Carbon Wire (Other Side of Card) October 25, 2006 Undulator Systems – BFW Diagnostics Ceramic card Vertical Carbon Wire (This Side of Card) Jim Bailey jbailey@anl. gov
BFW Prototype Setup Precision Screws Kinematic Stop Plates Engaged “Keyence” Sensors Supports Read Out Vacuum Line Fixed Frame Movable Assembly Pneumatic Cylinder Air Supply Line 70 psi Vacuum Chamber Bellows October 25, 2006 Undulator Systems – BFW Diagnostics Jim Bailey jbailey@anl. gov
BFW Prototype Setup Fixed Bottom Plate Movable Assembly Bellows Extended October 25, 2006 Undulator Systems – BFW Diagnostics Locking Screws w/ lock washer Locking Collar Precision Screws in Top Fixed Plate Jim Bailey jbailey@anl. gov
BFW Prototype Setup Precision Screw-Horizontal Adj. October 25, 2006 Undulator Systems – BFW Diagnostics Spring Loaded Positioner Jim Bailey jbailey@anl. gov
BFW Prototype Results Vertical Repeatability: +/-7 Microns Horizontal Repeatability: +/- 14 Microns (Extrapolated to account for lever arm) Adjustability: +/- 2 Microns Required Force on Kinematic Stop: 20 lbs. Slide Rod Clearance: 0. 020” Top Locking Screws: Lock Washers OK October 25, 2006 Undulator Systems – BFW Diagnostics Jim Bailey jbailey@anl. gov
Bench Adjustment (Initial and Replacement) Slide Fiducials Flange Locating Pins Bench Fiducials Adjustment Bench located on CMM Vertical and Horizontal Adjustment Screws Supply Air to Actuate Cylinder Wire Card Fiducials (Not Shown) Beam Center Line Based on Bench Fiducials October 25, 2006 Undulator Systems – BFW Diagnostics Jim Bailey jbailey@anl. gov
Installation and Replacement Alignment Strategy BFW Fiducials Undulator Fiducial Surface and Mount Hole October 25, 2006 Undulator Systems – BFW Diagnostics Undulator Side Fiducial Jim Bailey jbailey@anl. gov BFW Fiducials
Alignment Accuracy by Georg Gassner Graphical output of the SIMS simulation (front view) October 25, 2006 Undulator Systems – BFW Diagnostics Jim Bailey jbailey@anl. gov
Alignment Accuracy by Georg Gassner The alignment of the BFW in relation to the undulator segment is achievable with the given tolerances. The requirements given for the grand total uncertainty between the actual position of the so called “loose end” to the nominal position is 80 micrometers vertically and 140 micrometers horizontally (see PRD 1. 4 -004 -r 1). In the case of the BFW, this number includes the uncertainty of the undulator fiducialization, BFW fiducialization wire positioning repeatability, CAM positioning repeatability, Undulator segment roll away repeatability and alignment of the BFW to the Undulator. To get a better idea of the real numbers we did a simulation of the alignment parts, optical CMM (20 micrometer accuracy) and mechanical CMM (10 micrometer accuracy) with an alignment analysis simulation software package (SIMS 3. 6). The calculated uncertainty is 28 micrometers vertically and 40 horizontally for the CMM parts and results in a grand total accuracy of 60 micrometers vertical and 100 micrometers horizontal (1 sigma). For the calculation only random errors are considered, biased measurements will affect the results further. The main error sources remaining are the wire repeatability (30 mm / 80 mm) and the undulator fiducialization (40 mm / 50 mm). October 25, 2006 Undulator Systems – BFW Diagnostics Jim Bailey jbailey@anl. gov
Design Parameters Required actuating force: Slide Weight (11 lbs) + Vac. (15 lbs) + Bellows Spring (7 lbs) + Return Spring (15 lbs) + Stop (20 lbs) = 68 lbs Available Cylinder Force at 90 psi = 81 lbs Thermal Expansion Ref. For 304 SS at 10 in. (254 mm) height above girder exp. = 4. 5 µm/C October 25, 2006 Undulator Systems – BFW Diagnostics Jim Bailey jbailey@anl. gov
Wire Signal Connector Potentiometer Bellows Flange Vacuum System (Vents Vacuum Chamber) Support Girder October 25, 2006 Undulator Systems – BFW Diagnostics Interfaces Limit Switches Electrically Controlled Solenoid Valve Instrument Air Supply Undulator Fiducials Undulator Flange Beam Loss Monitors Jim Bailey jbailey@anl. gov
Final Design Review Held September 20, 2006 Significant issues of the design that were reviewed include: Design meets the requirements of the PRD and the ESD, Responses to preliminary design review comments, Reliability and practicality of the mechanical design, Wire card design, Fabrication and assembly considerations, Material selection, Vacuum compatibility, Alignment strategy (initial and replacement), Accuracy and repeatability of the wire placement (Review of prototype results), Environment considerations, Interfaces with adjacent components and systems, Control and monitoring requirements, Maintenance and wire replacement, Safety Reviewed approved fabrication drawing October 25, 2006 Undulator Systems – BFW Diagnostics Jim Bailey jbailey@anl. gov
Final Design Review Committee Report Recommendations: The ANL/SLAC team should proceed with the fabrication of the Beam Finder Wire Assembly and the BFW Support Assembly excluding the Wire Card Assembly. The Wire Card Assembly should have a design review after final material selections are complete. Transmittal Comment from FDR Chairman: ”The design team including the SLAC participants has done an excellent job on this hardware design. The prototyping effort is particularly appreciated. I am certain that the beam finder wire assembly will be successful. ” October 25, 2006 Undulator Systems – BFW Diagnostics Jim Bailey jbailey@anl. gov
Conclusions Open Items Need to modify the wire card design to accommodate carbon fiber wires. Need to incorporate suggested dimensioning comments and other drawing markups that were provided by the FDR committee. Design Status: After incorporation of final design review comments the design will be ready for the procurement process. October 25, 2006 Undulator Systems – BFW Diagnostics Jim Bailey jbailey@anl. gov
Conclusions Con’t Near Term Schedule Prepare procurement packages by 11/1/06 Place orders and award contracts by 12/1/06 Prepare assembly, test and alignment procedures by 3/1/07 Design and fabricate fixtures for above procedures by 3/1/07 Receive all parts by 3/1/07 Assemble, align, test and ship first three articles by 4/1/07 October 25, 2006 Undulator Systems – BFW Diagnostics Jim Bailey jbailey@anl. gov
Conclusions Con’t Project Schedule October 25, 2006 Undulator Systems – BFW Diagnostics Jim Bailey jbailey@anl. gov
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