ESR 3.1 Introduction
Iordan Doytchinov
26.05.2014
Contents:
 Who am I
 My MEng degree
 Industrial Placements and University Projects
 PACMAN project 3.1
I)
II)
Optimization of the Design and Assembly of the Main Beam Quadruples (MBQ)
for the CLIC Two Beam Modules – PhD thesis
Mechanical Integration of the PACMAN Assembly/Alignment Bench
 Current work plan, Training
 To do..
Me:
I come from here - Sofia
Beside Engineering…
Integrated Engineering MEng
Core/Integrated
Subjects
Electrical
Engineering
training
Mechanical
Engineering training
Mechatronics
Electronic
Devices &
Circuits
Mechanical
Design and
Materials
Selection
Robotics Engineering
Electromagnetic
Fields and Waves
Control
Engineering
Systems
modeling/
simulation
Thermal and
Fluid Mechanics
Vehicles
Dynamics
Complex Interdisciplinary projects
Engineering and Design
Industrial Placements Projects/MEng
Thesis
Siemens – Test automation - 1 year
National Met Office UK:
UAV Performance Estimation /system Integration
F4E – Vehicle Dynamics/ Performance - 3 months
Omron ltd Barcelona:
Real-Time HIL robot dynamics simulator (Master THESIS)
PACMAN 3.1 - Objectives
I) Optimization of the Design and Assembly of the Main Beam Quadrupoles (MBQ) for
the CLIC Two Beam Modules - main for PhD Hypothesis
One off prototype example: Dominique Loiseau - the Rose de Temps clock
Extremely costly on time & money
High number production (thousands): ‘Swatch’ mass production of
Swiss made high quality wrist watches
II) Mechanical Integration of the PACMAN Assembly/Alignment Bench
Babylon tower by Tobias Verhaecht (1561 – 1631)
“If you grasp the principles – myths fall & Ideas
take-off” David Lentink (TUDELFT) TED
Conference Amsterdam
(“ ‫ "برج خليفة‬,Khalifa Tower“) – Dubai 2010
I) Optimization of the MQQ Design & Assembly
Optimize magnet mechanical-magnetic design and assembly procedure from point of
view of ultra precision engineering.
Beam Dynamics magnetic
field Spec
The desired function! Our Meca!
Component design
Quadruple Yoke prototype example
By Raphael Leuxe
Good Field Region
(GFR) Specification:
- R(GFR) = 4mm
-
∆𝑮
= 0.1%
𝑮
Understand relationship?
Field Spec VS
Mechanical/Assembly spec
Assembly procedure/jig
(easy, cheap, fast)
Quadruple Yoke prototype example
By Raphael Leuxe
The Precision Engineering View
“There is not such thing as bad ‘function’ delivered by assembly/component. All
functions are ‘perfect’ and acts according to its intentional or unintentional design.
There is only a ‘bad’ or not well understood design.”
 Understanding of real material geometry as function of environment and itself
(temperature, gravity, coupling forces).
 ‘Right’ Kinematic design (restriction of the right degrees of freedom)
 The insurances of the ‘right’ measurement met
 Design for repeatability. (high stiffness design – low histersis, attenuation due
thermal, vibration effects).
 Other..
Current Tasks for I)
 Understanding of the ‘scale’ of the problem. Internship in Metrology
department – Accuracy, Uncertainty, Resolution, Repeatability,
Reproducibility and Tractability of micrometric measurement at 2m length
scale. The same activity to be performed at DMP Spain!
 Understanding of the current state of art – Assembly with mounting key
design.
 Investigation of perfect possible mechanical assembly from CMM
measurement of prototype parts (KOTEM software)
 Understanding of beam dynamics specification in the contexts of
mechanical specification (Daniel Schulte), FEA magnet Simulation software,
KOTEM
 Material selection for the magnet? Investigation on best material for point
of view of magnetic and high precision mechanical design (Ashby analysis)
II) Mechanical Integration of the PACMAN
Assembly / Alignment Bench
• Specifications coordination (by Iordan Doytchinov):
Act as system engineer making sure all the subgroups specification Integrate
in appropriate way:
 QFD analysis to be performed as practice for wire integration case study
- Understanding of the complete specification
 Possible Ashby analysis for selection of hybrid material for the wire.
• A GLOBAL mechanical/assembly INTEGRATION aspect (by Iordan Doytchinov)
 BPM sensor mechanical alignment and integration to MBQ magnets
- BPM integrated with beam pype?
- BPM as part of the MBQ?
- Other solution such as separate stand or integration to MBQ stand
II) Mechanical Integration of the PACMAN
Assembly / Alignment Bench
• A GLOBAL mechanical/assembly INTEGRATION aspect (by Iordan Doytchinov)
 Electromechanical integration of magnetic, RF and metrological wire measuring tools
into single one (one wire, one stretching system)1 Wire and support structure for 2 to 4
different measurements: (RF BPM, RF ACC structures, MBQ Magnetic field position and
quality, Metrological reference )
II) Mechanical Integration of the PACMAN
Assembly / Alignment Bench
• A GLOBAL mechanical/assembly INTEGRATION aspect (by Iordan Doytchinov)
 To perform the full mechanical integration of the prototype alignment bench (which
will fit on Leitz CMM) make sure all sensor, control actuators systems integrate
electromechanically. All ultraprecision design techniques to integrate various
subsystems into the final PACMAN stand
Current Work Plan, Training
Current work:
Study Assembling of DMP prototypes with mechanical KEY method developed
- Use KOTEM smart fit software (http://www.kotem.com/Pages/SmartFit.htm) to study best fit of
components
Wire integration case study for 2x systems (Magnetic and Metrological). Practice QDF (Quality
Function Deployment) and component analysis to select appropriate wire and stretching systems.
Training:
So far 3day basic ISO GD&T course; 1 day Faro arm course
 To do: - 10 Day CATIA course
- 6 Day ANSYS course
- Internship Metrology department,
- High Precision engineering course at Cranfield
- Other
To Do

Create detailed work, training plan, define Scientific Hypothesis on Part I

Identify Risk Metrics and redesign work/training plan with accordance to it:
Thank you for
listening
Your feedback?
QFD
“CUSTOMERS”:
 Magnetic measurement
 Mechanical Measurement
 RF Measurement BPM
 RF Measurement Acc structures
Ashby analysis Hybrid Material