XLS CAD model - Indico
Transcript of XLS CAD model - Indico
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[email protected] XLS www.CompactLight.eu 1
XLS CAD model
Nick Gazis, Eugene Tanke,
Andrea Bignami, Emmanouil Trachanas, Evangelos Gazis
IASA & ESS Team
16 June 2020
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Funded by the
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[email protected] XLS www.CompactLight.eu 2
Outline1. Introduction of 3D CAD MODEL
2. CAD/CAM System CATIA V5 & V6
3. 3D CAD: Study Case the XLS-Injector
4. 3D CAD model for XLS based on the baseline layout
5. Girder Analysis
6. Requests from CAD modelers to XLS Collaboration
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1. Introduction of 3D CAD MODELA 3D model provides benefits such as:
It aids in planning and design (e.g.– conceptual design during the
conceptual phase)
It aids in integration activities: The 3D models can be used to support vision sharing, and they help
discovering, resolving design issues early (e. g. clashes, interfaces,
assembly clearances etc.) and the models can be readily available for
FEA simulations
It is the smart modern way of design – avoiding the need for an army
of designers and engineers
Our 3D model can range from the overall XLS layout down to detailed
models of individual accelerator components
It can serve as a repository of the 3D designs (XLS Engineering Data
Management System-EDMS repository)
This presentation explains the modeling technique and shows examples of
model usage
Why a 3D CAD XLS model?
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2. CAD/CAM System CATIA V5 & V6
Our CAD team has been using CATIA V5 & V6 and is available to support XLS at
the appropriate level of detail for design studies.
• This platform is typically used for medium or large technical designs as it can
handle tenths of thousands of unique designs and specs.
• User Friendly (light representations) of the models can be imported in freeware
software (Navisworks) for simple use (e.g. distance measurements, presentation
discussions) in different OS (Windows, Mac etc).
• 3D-models and 2D-drawings can be produced on the same platform with the
capability of using version control and design evolution validation
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2.5 cells gun
Gun solenoid,
bucking coil
Mode
Launcher
Cathode plug
Coupler
location
Drift 0.7m for
diagnostics
3. 3D CAD: Study Case the XLS-Injector 2.5 Cell Gun
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3. 3D CAD: Study Case the XLS-Injector 1.6 Cell Gun
CST Eigenmode analysis
A preliminary 1.6 cell cavity was used
to perform first Eigenvalue simulations
without excitation.
Tetrahedral Mesh was used with the
method AKS (Advanced Kyrlov Subspace)
for the first 35 EM modes.
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3. 3D CAD: Study Case the XLS-Injector
CST Magneto-Static analysis
Gun Solenoid
Field distribution
Result is in between Emmanouil’s
and Alessandro’s field values
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3. 3D CAD: Study Case the XLS-Injector TW Solenoids
CST Magneto-Static analysisThe 3D file was imported in CST studio to perform a magneto-static simulation.
Steel-1008 was chosen for yoke material, as the lowest carbon-steel percentage available in CST library. Annealed Cu was
chosen for the coil material. Coils were defined with the CST coil tool, inserting the same amount of current, ampere turns
and resistivity as presented in the solenoid parameters. The result in the center of the solenoid on the beam axis is 0.22 T
(magnetic flux density), same value obtained by SUPERFISH also.
Field distribution
Results H filed, B filed, Magnetic
Energy Density and comparison
with SUPERFISH results:
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3. 3D CAD: Study Case the XLS-Injector
Low carbon steel yoke 120 cells TWS Solenoids with common yoke
4 coils ~0,5m -> 0.22 T field
Injector TWS
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Travelling wave
structures with
solenoids on
Linac 0
SwissFEL girder
Reference: SwissFEL Conceptual Design Report
Injector TWS
Girder design for XLS inspired by SwissFEL girder
3. 3D CAD: Study Case the XLS-Injector
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3. 3D CAD example XLS-Injector with Girder
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2.5 cell gun
120 cell TWSgirder
Section view until laser heater
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Full C—band XLS Injector • One injector for all the operational modes (HRR and LRR)
Ø 2.5 C-band gun with 160 MV/m cathode peak field => longer dr ift for diagnostics
Ø Copper cathode and TiSa Laser
Ø Same gradients 15 MV/m in the 2 m long C-band str uctures, max gain 30 MeV/str ucture
Ø Same diagnostics posit ions (@ gun exit 7 MeV and in the dr if t parallel to the LH @ 120 MeV)
Ø Same beam parameters at the linac exit
Ø Matching with LH to be deter mined
• Optimal BC1 input energy (=> and posit ion) to be deter mined
Ø Without Velocity Bunching
Ø With Laser Heater less than 2 m long
Ø K-band Linear izer just before the BC1, X-band RFD downstream BC1
Ø Same beam parameters at the BC1 exit
Ø Matching with BC1 to be deter mined
2.5 C-band Gun 160 MV/m
Diagnostics Section @ 7 MeV
2 m long C-band structures =15 MV/m
Laser Heater @ ~120 MeV with matching 1.5 m
Diagnostics Section @ ~120 MeV 3 m
2 m long C-band structures =15 MV/m
K-band Linearizer
Bunch Compressor 1 @ < 300 MeV
X-band Deflector
~25 m
3. 3D CAD example with XLS-Injector for our next steps
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3. 3D CAD: XLS-Injector case study
Laser Heater
location
BC1
Gun
Gun and injector setupK-linearizer and X-band
deflector to be included
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3. 3D CAD example with XLS-Injector
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X-band structure
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4. 3D CAD model for XLS based on full baseline layout
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This baseline layout will be followed; taking into account any further
improvement.
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3. 3D CAD example with XLS-Injector linac with Girder
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Example of Linacs 1, 2 & 3 X-band structures on girders
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4. 3D CAD MODEL for XLS injector in the tunnel
*MCS: Machine Coordinate System
(as well as the location of the Interaction Point with
X-ray generation) will need to be defined for XLS
Z axis
(beam)
Y axis
(vertical)
X axis
(transversal)
MCS*
(0,0,0)
Tunnel roof,
in this example shown at
3.5 meters from the tunnel floor
3.5
m
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5. Girder Choice: Points to keep in mind
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• Modular design of component “clusters” is imperative for a
compact machine
• Common girders allow for compact pre-assembly, extensive
part testing and reduce drastically the installation time
• Tolerances, machine precision and alignment degrees of
freedom will seriously impact the cost profile of the accelerator
• Active repositioning or passive alignment is a choice dictated
by beam tolerance and machine alignment budget
• Investing in CAD design & integration combined with
supporting system study in this stage will reduce errors of
manufacturing, assembly and future needs for spares
This implies that analysis of the girders will be required
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5. Girder Analysis: Few options for supports and alignment
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Prestressed isolating girders
with active alignment
Damping girders with high-
frequency absorption capacity
Individual girders
CERN CLIC
CTF & CLEX
PSI
MAX IV
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5. Girder ANSYS simulation
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Material: ANSYS Structural Steel for girder material
Geometry: This version of XLS girder is the exact transposition from the MAX IV’s girder model
Max stress concentration on the
spherical joint, between the horizontal
support and the legs that allows to orient
the horizontal plane on which the round
supports are mounted
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6. Requests from CAD modelers to XLS Collaboration
In order to efficiently integrate the XLS accelerator beam line elements
in the 3D model, the following information would be needed:
1. Quantity and types of beam line elements
2. Size and Position (e.g. relative to e-gun cathode) of each beam line
element and of their internal structure, where possible
3. Space needed for the beam instrumentation parts, deflectors, etc.
4. In order to have a 3D model of the entire facility, the scale of the
model should be given by the collaboration
All colleagues are welcome to contact us and request
CAD modelling of their parts, integration of designs, etc.!
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References
1. L. Hagge, J. Kreutzkamp, S. Lang, S. Suehl, N. Welle, Examples for 3D CAD
Models at the European XFEL, Conf.Proc.C 1205201 (2012) 3266-3268
2. L. Hagge, J. A. Dammann, T. Hongisto, D. Käfer, J. Kreutzkamp, B. List, S.
Rohwedder, S. Sühl, N. Welle, ENGINEERING DOCUMENTATION AND
ASSET MANAGEMENT FOR THE EUROPEAN XFEL ACCELERATOR,
Proc. IPAC2017, 3960-3962
3. N. Bergel, L. Hagge*, T. Hott, J. Kreutzkamp, S. Sühl, N. Welle, INTER-
DISCIPLINARY MECHANICAL AND ARCHITECTURAL 3D CAD DESIGN
PROCESS AT THE EUROPEAN XFEL, Proc. EPAC08 1467-1469
4. R. Dubovska, J. Jambor, J. Majerik, Implementation of CAD/CAM system
CATIA V5 in Simulation of CNC Machining Process, Procedia Engineering 69
(2014) 638 – 645
5. N.Gazis, E.Tanke, M.Lindroos, M.Tacklind, P.Radahl, K.Jonsdottir,
Mechanical Engineering, Design and Structural Health Monitoring at the ESS
facility to enable science, Int. J. Mod. Phys., World Scientific, under publishing
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Thank you!
CompactLight is funded by the European Union’s Horizon2020 research and innovation programme under Grant Agreement No. 777431.
[email protected] www.CompactLight.eu
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Back-up slides
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A compact linac does not only
contain the accelerating parts but
also the power sources, electronics,
controls, waveguides, cooling
sources etc. and assembly that
need design and space to fit in DTL
Operational DTL
DTL assy dwg
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1. Space reservation 2. Preliminary Design 3. Detailed Design
4. Manufacturing launch 5. Installation Review 6. Testing
7. As-Scanned 8. As-Built & Commissioned