CLIC Permanent Magnet Quadrupole update 1 st December

CLIC Permanent Magnet Quadrupole update 1 st December 2010 Mechanical Engineering status N. Collomb 1

Presentation Topics • Integration issues from previous iteration • Design revision and envelope check • Development comparison and dimensional changes • Assembly Sequence considerations • Future plans • Corrector Feature N. Collomb 2

Integration issues Motor posed an issue N. Collomb 3

Integration issues Gearbox bracket interfering with vacuum pump Mechanism clash with Flange and Vessel Interference clash with girder N. Collomb 4

Integration issues • CAD-QA showed clashes in integration model – – – Motor and Flange Mechanism and vacuum vessel Gearbox bracket and vacuum pump Mechanism brackets on ‘front’ and girder Height and girder interface • Magnet aperture was larger than specified • BPM coupled to magnet • Shimmed vacuum vessel prevented correction in vertical and horizontal plane. N. Collomb 5

Revision of mechanical design • Reduction in width to prevent clashes • Remodelling with respect to magnetic design update • Correction of aperture • Review of components due to forces change and clashes • Assembly process instigation and design implications • Interface with girder consideration • Correction features N. Collomb 6

Placed box on girder. Box: 391 x 270 mm Envelope check No interference Interference No interference, just N. Collomb 7

Current Development 1. 2. 3. 6. 7. 5. 4. N. Collomb Major changes: 1. Motor moved to top (vertical) 2. T-Gearbox different 3. Side-plate with rails continuous 4. Core – faceplate redesigned 5. Yoke Assembly redesigned 6. Cap – faceplate size reduction 7. Ball-screw nut bracket shallower and 1 piece Previous schematic 8

388 mm (385) Nosepole aperture: Ø 28 mm Aperture Ø 70 mm 850 mm (654) Dimensions (figures in brackets from previous schematic) 230 mm magnet 260 mm 330. 5 mm (368. 5) 398. 5 mm (438. 5) N. Collomb 270 mm (262) 9

Assembly Sequence • Initial strength calculations indicate feasibility of design is OK. • Discussion with manufacturers about subassemblies in progress – influences assembly sequence. • Design broken down into 5 key stages – – – Magnet core Core Linear motion system Motor and Gearbox Final Assembly N. Collomb 10

Assembly Sequence – Magnet Core Supplier provides assembly: Magnetic steel centre Strap plate to prevent mechanical failure Permanent Magnet N. Collomb Alu Strap: tensions Strap and supports PM Magnetic steel plate 11

Assembly Sequence - Core can be split into ‘Top’ and ‘Bottom’ halves. Face – plates maintain horizontal positioning, Core supports maintain vertical positioning to ensure inscribed nose-pole radius is accurate. Magnet Cores (top removed for clarity) serve as reference. Face - plates Alu Core support (doweled) Magnet Core (ref) N. Collomb Magnetic steel Yoke 12

Assembly Sequence – Linear Motion System Side Mounting Plate Linear Motion Rails Ball-screw nut bracket Ball-screw nut Adjustable Ball-screw Support bearings N. Collomb Linear Motion Runners Could reduce magnet overallwidth by 20 x 2 mm at cost of backlash couplings. 22 mm 13

Assembly Sequence – Motor & Gearbox 400 step/rev Stepper motor, 1. 8° accuracy T- Gearbox ratio 2: 1 Backlash coupling Right Angle Gearbox ratio 25: 1 Brackets can be combined into one piece, still permitting alignment. N. Collomb 14

Assembly Sequence – Top Level Core Magnet Assembly and Core brought together in controlled manner in jig. Dowelled and secured. N. Collomb Step 1 is to fasten Sideplate Assembly to Centre Assembly. Secured only. Step 2 is to fasten Faceplates. Align and adjust as required. (D. o. F. ) Dowelled and secured. 15

Assembly Sequence – Top Level Backlash Coupling and Gearbox bracket preassembly. Secured only Motor and Gearbox assembly lowered onto ball screw ends align and secure before pre-tensioning. Dowelling. Motor conditioning. Single gearbox assembly bracket in progress. N. Collomb 16

Assembly effects for manufacturing • Outsourcing certain sub-assembly advantages are the expertise and infrastructure manufacturers possess. • Collaboration with manufacturers has started (hypothetical mass production discussions). • Some components can be eliminated by incorporating their function into one part. • Splitting the magnet is still possible to insert the vacuum chamber during installation – however I propose to include the vacuum chamber during initial assembly. N. Collomb 17

Revision of future plans • Revise time of deliverables – – – – FEA and optimisation (partially complete) – Jan 11 Design evaluation (in progress) - Dec 10 Assembly plan (in progress) – Dec 10 Integration (model send to Dimitry) – Nov 10 Design and development of corrector – Jan 11 Costing and procurement – Feb 11 Prototyping – June/July 11 Assembly/Testing – July/Aug 11 N. Collomb 18

Corrector feature • Integration illustrations indicate that this feature must be located on the side on the girder magnet interface. • It MUST NOT add height other than what is required • Aperture permits a ± 1. 4 mm vertical or horizontal movement (Magnet aperture Ø 28 mm and Vacuum vessel O. D. 26 mm) • Requirement for movement ± 0. 5 mm means we can reduce the magnet aperture to Ø 27 mm (± 0. 7 mm achievable). N. Collomb 19

Corrector feature • Interface between magnet and girder not designed yet. • Design to commence once integration has cleared magnet envelope. • Questions: – Can the girder be modified in terms of additional holes for instance? – Do other components occupy space below reference surface adjacent to magnet? – Is the girder hollow and if so can we mount items from underneath? – Can you supply a model of the girder (blank)? N. Collomb 20

Summary • We are closing in on a feasible design. • Provided the integration shows the magnet can fit in the space allocated on the module, then a prototype can be started to be procured in February 2011. • Manufacturers are keen and provide advice and guidance in terms of cost – functionality. • Accuracy, repeatability and precision can be achieved to meet specification. • Time plan has slipped slightly with prototypes still available for third quarter 2011. • James Richmond continues on project as part of his University degree. N. Collomb 21

Questions? N. Collomb 22