Robert Ruland

MMF Introduction, Schedule, Budget ruland@slac.stanford.edu

October 14, 2004 MMF Review 1

MMF Introduction, Schedule, Budget

Robert Ruland

MMF Introduction, Schedule, Budget

Robert Ruland

Design Driving Requirements

Magnetic Measurements Facility (MMF) CapabilitiesMagnetic Measurements

Fiducialization

Storage

Magnetic Measurements FacilityLocation, Construction Schedule

Implementation Schedule

Manpower

Summary

Design Driving Requirements

Magnetic Measurements Facility (MMF) CapabilitiesMagnetic Measurements

Fiducialization

Storage

Magnetic Measurements FacilityLocation, Construction Schedule

Implementation Schedule

Manpower

Summary

Robert Ruland

MMF Introduction, Schedule, Budget ruland@slac.stanford.edu

October 14, 2004 MMF Review 2

MM Test Bench Design Driving Requirements

Magnetic Measurements / TuningThe measured values for Keff shall be within ± 0.0005 (i.e., ± 0.015%) of the design values(LCLS Undulator Requirements PRD 1.4 – 001)

Alignment / Fiducialization -Undulators-Relative alignment of undulator to BBA quadrupole driven by sensitivity of K to position,1.5*10-4 is correlated to 70µm in Y, to achieve this requires finding the magnetic CLund to 20µm and the CLquad to 10µm

Robert Ruland

MMF Introduction, Schedule, Budget ruland@slac.stanford.edu

October 14, 2004 MMF Review 3

MMF Design Driving Requirements Undulator – to – Quad Relative Alignment

Quadrupoles are aligned to straight line using BBAUndulators need to follow quadrupole positionCritical relative alignment tolerance of 70 µm in YExtremely difficult to achieve in tunnel environment with conventional alignment methodsSolution: Undulator and Quad integrated on common support, relative alignment performed in laboratory using CMM

Design requirement: accurate magnetic CL determination for quad, undulator as well as CMM for control of relative alignment

Robert Ruland

MMF Introduction, Schedule, Budget ruland@slac.stanford.edu

October 14, 2004 MMF Review 4

Required MMF Tasks

TuneImplement magnetic measurements equipment to measure and tune Keff to within ± 0.0005

Determine magnetic CL Implement magnetic measurements equipment to determine magnetic centerline for quadrupole and undulator to within ± 10 µm and ± 20 µm, respectively.

Mechanical Fiducialization Correlate magnetic axis to fiducials for quadrupole and undulator

Alignment ControlPerform control of relative alignment quadrupole to undulator

AssemblyImplement assembly capability to integrate components on common support

Robert Ruland

MMF Introduction, Schedule, Budget ruland@slac.stanford.edu

October 14, 2004 MMF Review 5

MMF Set-up

Magnetic MeasurementsUndulator Test Bench #1 (7 m)final gap setting, final tuningUndulator Test Bench #2 (4 m) – existingprototyping procedures, software development, initial gap settingHall Probe Calibration SystemTest magnet and NMR systemQuad Integrated Field Strength BenchStretched WireQuadrupole Fiducialization PlatformVibrating WirePointed-Magnet Fixture Calibration Bench

Fiducialization & AssemblyFiducialization CMM 4.2 mQuadrupole Fiducialization PlatformVibrating Wire mounted on CMMBPM, Diagnostics Fiducialization

AssemblyCradle Assembly BenchVacuum Chamber Alignment BenchGranite table with Height Gauge

Undulator Segment / Cradle Storage

At least 2 Und. Segments in MM lab (0.1º C)

At least 2 Und. Segments in F&A lab (1º C)

8 Cradles, quads, BPMs, Vacuum chamber and misc. supports in F&A lab (1º C)

About 20 undulator segments / cradles in storage area (2.5º C)

Magnetic Measurements Facility Requirements, PRD 1.4 - 002

Robert Ruland

MMF Introduction, Schedule, Budget ruland@slac.stanford.edu

October 14, 2004 MMF Review 6

Layout

Floor plan divided into three functional areasMagnetic Measurements (± 0.1º C)Fiducialization and Assembly (± 1º C)Storage (± 2.5º C)

Test stand lay-out is driven by requirement to match the Earth Magnetic Field conditions in lab to Undulator Hall, i.e. azimuth and gap orientation need to be identical

Robert Ruland

MMF Introduction, Schedule, Budget ruland@slac.stanford.edu

October 14, 2004 MMF Review 7

Undulator Test Bench8m Test Bench Implementation

ScheduleFirst article undulators will

arrive at SLAC around March 2006Production undulator delivery

commences in summer 06BO MMF estimated Febr. 06Not enough time to complete

integration, software development, testing and commissioning before first undulators arrive

Upgrade 4m bench obtained from APS with equivalent hardware as 8m bench to serve as test bed for software development and procedure testing.

Will be using second bench for preliminary gap setting will help production schedule

Robert Ruland

MMF Introduction, Schedule, Budget ruland@slac.stanford.edu

October 14, 2004 MMF Review 8

Undulator FiducializationProposed Method: Pointed Magnet Fixture

Step 1: measure offset between undulator axis and pointed-magnet reference fixture on MM BenchStep 2: Measure pointed-magnet reference fixture wrt undulator fiducials on CMM

Robert Ruland

MMF Introduction, Schedule, Budget ruland@slac.stanford.edu

October 14, 2004 MMF Review 9

Quadrupole Fiducialization

Finding the axisBased on Vibrating Wire or Pulsed WireHave Pulsed Wire prototype setup. Routinely achieve repeatabilities even in environment with wide temperature swings of better than 5 µmAlso have Vibrating Wire prototype set-up. It promises better yaw and pitch resolution. Implementation based on setup by Dr. Temnykh from Cornell

Transfer onto quadrupole fiducialsUse Wire Finders (developed for VISA) to locate wire and reference to its tooling ballsUse Coordinate Measurement Machine (CMM) to transfer information from WF to Quad fiducials.Vibrating Wire system will be mounted onto optical table which can be set-up on undulator fiducialization CMM

Robert Ruland

MMF Introduction, Schedule, Budget ruland@slac.stanford.edu

October 14, 2004 MMF Review 10

SLAC LCLS Magnet Measurements Facility

SLAC presently does not have a facility to perform the magnetic measurements tasks necessary for LCLS with the required accuracy: Need to build new facility.Proposed Location: Bldg 81, about 0.8 km away from tunnel

Sufficient power for HVAC & test equipmentGround motion and vibration measurements did not indicate potential problemsManageable space constraints

Robert Ruland

MMF Introduction, Schedule, Budget ruland@slac.stanford.edu

October 14, 2004 MMF Review 11

Facility Construction & Design GoalsFunding

Long Lead Procurement Funds, available in FY05Building & Climate Control K$1,400

Construction ScheduleT1 Aug 04 (Engineering)T2 Dec 04 (Final Construction Drawings)T3 May 05 (Construction Start)Beneficial Occupancy February 2006 (early finish 11/05)

Design SpecificationsFull set of specs: LCLS-TN-04-1 Z. Wolf, R. Ruland, "Requirements for the Construction of the LCLS Magnetic Measurements Laboratory“. Magnetic Measurements Lab: Temperature stability of ± 0.1º C, short term temperature swings of up to 0.3 ºC with less than 1 hour duration are acceptableFiducialization Lab and Assembly Area: Temperature stability of ± 1º CStorage Area: Temperature Stability of ± 2.5º C

Robert Ruland

MMF Introduction, Schedule, Budget ruland@slac.stanford.edu

October 14, 2004 MMF Review 12

Measurement Equipment

$514,480

$114,875

$517,751

$53,410

$33,463

$126,952

$133,000$165,311 Undulator Test Stand

Undulator Test Stand Proto

Undulator Fiducialization System

Quad Fiducialization System

Quad Strength and Field Quality

Hall Probe Calibration System

Undulator Handling

BPM & Diag. Fiducialization

Robert Ruland

MMF Introduction, Schedule, Budget ruland@slac.stanford.edu

October 14, 2004 MMF Review 13

Test Stand Implementation Schedule

Robert Ruland

MMF Introduction, Schedule, Budget ruland@slac.stanford.edu

October 14, 2004 MMF Review 14

Test Stand Implementation ScheduleSchedule needs to be adjusted for effect of Continuing Resolution

Robert Ruland

MMF Introduction, Schedule, Budget ruland@slac.stanford.edu

October 14, 2004 MMF Review 15

Test Stand Implementation ScheduleSchedule needs to be adjusted for effect of Continuing Resolution

Robert Ruland

MMF Introduction, Schedule, Budget ruland@slac.stanford.edu

October 14, 2004 MMF Review 16

Manpower

We have mostly ramped up the staffing in the Magnetic Measurements Group to cope with the MMF work and at the same time to allow our conventional work to continue.

MMF Development1 Senior Physicists2.5 Engineering Physicists1 add. Eng. Physicist (starts Jan. 1, 2005)1 Metrology Engineer2 Technicians1 add. Technician (starts Jan 1, 2005)

Conventional Work1 Senior Physicist0.5 Engineering Physicist1 Technician1 Research Assistant

Will be able to handle Undulator Production Measurements with existing manpower, supplemented with help from the Alignment Engineering and Quality Inspection Groups. There is no other significant competing work scheduled.

Robert Ruland

MMF Introduction, Schedule, Budget ruland@slac.stanford.edu

October 14, 2004 MMF Review 17

ENDof

Presentation

Robert Ruland

MMF Introduction, Schedule, Budget ruland@slac.stanford.edu

October 14, 2004 MMF Review 18

Fiducialization Accuracy RequirementRequired fiducialization accuracy is driven by error budget for aligning undulator wrt to beam-based-aligned quad, i.e. in order to stay within the total error budget of 70µm vertically, quadrupole fiducialization needs to done to 25µm and undulator segments need to be done to 40µm (see PRD1.4-001 General Undulator System Requirements)

Vertical Horizontal Quadrupole Fiducialization Pulsed Wire Center Definition 10 m 10 m Wire to Wire Finder Fiducial (WF) 15 m 15 m WF Fiducial to Quadrupole Fiducial 10 m 10 m 25 m 25 m Quadrupole BBA Offset (rms) 20 m 20 m Undulator Fiducialization Hall Probe Positioning / Resolution 20 m 20 m Needle Hall Probe Resolution 10 m 30 m Needle Hall Probe to Mechanical 20 m 30 m Needle Fiducial to Undulator Fiducial 20 m 20 m 40 m 50 m Undulator Segment Roll-away Repeatability 20 µm 20 µm Alignment Quadrupole to Undulator 40 m 40 m Grand Total 70 m 80 m

Robert Ruland

MMF Introduction, Schedule, Budget ruland@slac.stanford.edu

October 14, 2004 MMF Review 19

7 m Test Bench Specifications Outline

Total travel length in Z 7000 mm.Make carriage as long as cost wise reasonable to minimize yaw, at least 1000 mmMake bench cross-section as large as reasonable, min 800 mm wide, 500 mm highTravel length in X as much as bench width permits, min 300 mmTravel length in Y: 100 mm or more if w/o loss of accuracyGranite base straightness in Z and X: ± 10 µm Position accuracy at probe tip required Z, X, Y: 5 µm, 20 µm, 20 µm, desired: 3 µm, 10 µm, 10 µm.Z-axis drive linear motor with 1 µm positioning resolutionX, Y axes drive lead-screw with 1 µm positioning resolutionNo stepping motor on any axisZ position measurement with incremental encoder type Heidenhain LIDA, a second encoder on opposite side of bench could be considered to monitor yaw rotation of carriageX, Y axes motion measured with Heidenhain glass scale encodersPerpendicularity of X and Y axes to be better than 0.1 mradProbe axis be equipped with rotary stage with 0.01º resolution and 4-axes goniometerSupport bench on foundation separate from laboratory floorSupport undulator independent from bench on common foundationSupport cable carrier independent from bench on common foundationEquip cable carrier with drive system synchronized as slave to Z-axis drive