LCLS
Single Undulator Test and
Integration
Geoff Pile
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
LCLS
Overview of results from the
Single Undulator Tests
Information taken from various presentations of “An Internal
SUT review”
Thanks to the SUT construction team.
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
Our First Renderings of the SUT
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
LCLS
Original Goals of the Single Undulator Test
LCLS
Provide critical input to the S/M system design reviews.
Help to determine whether the support/mover system
design is ready for final production.
Measurement of girder and rollaway motions
Determine precision and reproducibility of motions,
including start and stop. Check for interference
Measure vibration damping or (hopefully not) amplification.
Measure position stability and temperature dependence of
components and subcomponents.
Practice Undulator replacement technique on SUT
translation stages
Enhance the Final Integrated Design for production
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
LCLS
The actual SUT set up in MM1
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
LCLS
The Test Plan Included
Support Mover System Testing
Control System Testing
Mock Vacuum System Testing
Diagnostic & Quad System Testing
Kinematic Undulator Replacement
Alignment Checks/Tests
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
LCLS
Support/Mover System Testing
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
LCLS
Support/Mover System Testing
Salient Support/Mover System Physics Requirements:
• Quadrupole Motion Positioning Repeatability
• Quad. Center Stability after Fiducialization
• Short-Term (1 h) BPM and Quad Stability
• Long-Term (24 h) BPM and Quad Stability
±7 µm
±10 µm
±2 µm
±5 µm
• Horiz. Segment Pos. Repeatability in Roll-Away Cycle
• Vert. Segment Pos. Repeatability in Roll-Away Cycle
±10 µm
±5 µm
• Quad Transverse Position Change in Roll-Out Condition
• Quad Position Reproducibility after Roll-Away Cycle
• BPM Transverse Position Change in Roll-Out Condition
• BPM Position Reproducibility after Roll-Away Cycle
±25 µm
±2 µm
±25 µm
±2 µm
* Note: The MM1 Facility Lacks Adequate Temperature Control
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
Support Mover System Testing
SUT Keyence CCD Laser Displacement Sensor
Layout
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
LCLS
Support/Mover System Testing
Sensor Name
LCLS
Measuring Range
Resolution
XUpstream
± 5 mm
0.05 µm
Horizontal Upstream Beam Center Position; BFW Manual Stage
YUpstream
± 5 mm
0.05 µm
Vertical Upstream Beam Center Position; BFW Manual Stage
XDownstream
± 5 mm
0.05 µm
Horizontal Downstream Beam Center Position; BPM Manual Stage
YDownstream
± 5 mm
0.05 µm
Vertical Downstream Beam Center Position; BPM Manual Stage
YMidstream
± 5 mm
0.05 µm
Middle Edge of Girder at Beam Height for System Roll
XQuad
± 5 mm
0.05 µm
Horizontal Position at Beam Height for Quad Manual Stage
YQuad
± 5 mm
0.05 µm
Vertical Position at Beam Height for Quad Manual Stage
XUpstream Translation
± 40 mm
0.5 µm
Upstream Undulator Segment Position for Roll-Away System
XDownstream Translation
± 40 mm
0.5 µm
Downstream Undulator Segment Position for Roll-Away System
YFloor 1
-250 mm/+500 mm
2.0 µm
Upstream Outboard Vertical Position of Girder Relative to Floor
YFloor 2
-250 mm/+500 mm
2.0 µm
Downstream Outboard Vertical Position of Girder Relative to Floor
YFloor 3
-250 mm/+500 mm
2.0 µm
Inboard Middle Edge Vertical Position of Girder Relative to Floor
12th October2006
Single Undulator Test and Integration
Sensor Measurement Function
Geoff Pile
pileg@aps.anl.gov
Support/Mover System Testing
XDownstream Translation
YQuad
XQuad
XDownstream
YDownstream
12th October2006
Single Undulator Test and Integration
YFloor 2
Geoff Pile
pileg@aps.anl.gov
LCLS
Support/Mover Roll out System Testing
LCLS Undulator Roll out Requirements 8.12
Wire center  40 mm (not in PRD)
in ID roll-out condition.
Girder Upstream
BPM/Quad center  25 mm
in ID roll-out condition.
Girder Downstream
Total weight: ~4060 lbs. ID weight: 2140 lbs.
ID motion range: 80 mm.
Load change max: ~ +/-350 lbs.
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
LCLS
Support/Mover Roll out System Testing
LCLS
Test Results with the Original System
Wire center X=16 mm, Y=37 mm
in ID roll-out condition.
Girder Upstream
CAM 4
CAM 5
BPM/Quad center X=103 mm, Y=10 mm
in ID roll-out condition.
Girder Downstream
CAM 1
12th October2006
Single Undulator Test and Integration
CAM 2
CAM 3
Geoff Pile
pileg@aps.anl.gov
Modified Downstream Wedge Blocks both from 45 to 25.6 and
43°
LCLS
Test Results with the Cam System swapped end to end
with 1 modified wedge block (overcorrected negative)
Wire center X=66 mm, Y=22 mm
in ID roll-out condition.
Girder Upstream
CAM 1
CAM 2
CAM 3
BPM/Quad center X=-23 mm, Y=-12 mm
in ID roll-out condition.
Girder Downstream
CAM 4
12th October2006
Single Undulator Test and Integration
Fully optimized
system meets spec
CAM 5
Geoff Pile
pileg@aps.anl.gov
LCLS
Modified Downstream Outboard Wedge Block from 45 to 25.6/41.9°
Readings from the Keyence Sensors During a Full Cycle of the
80 mm. Roll-Out and Roll-In Cycles (2 sets of data/round trip)
Displacement at the Beam Center
(microns)
The Effects of Girder Roll/Twist from the Roll-Away Cycle
80.0
70.0
60.0
50.0
40.0
30.0
20.0
10.0
0.0
-10.0
-20.0
-30.0
Xupstream
Yupstream
Xdownstream
Ydownstream
0
20
40
60
80
100
Roll-Away Position (mm.)
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
Support/Mover System Testing
LCLS
Conclusions:
• The Cam-Mover System Tests Resolution and Backlash Results are
Excellent for all Degrees of Motion Freedom and Well Within
Specifications
• With Feedback Added, The Cam-Mover System is Able to Achieve Any
Move Within the Command Space to Within 2 µm with No More Than One
Iteration
• The Roll-Away System Backlash and Resolution Results are Excellent
and Well Within Specifications
• All Motions for Both Motion Systems are Extremely Repeatable
• With the New Gearbox Design Motor Heating Effects are Non-Existent
• Engineering Solutions to Make the System Even Better are Underway
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
LCLS
Control System Testing
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
Control System Testing
LCLS
• The electronic rack for the
SUT incorporates most of the
hardware control systems for
the undulator components.
• It requires 120 volts and an
Ethernet connection.
• The real rack will conform to
SLAC rack systems &
earthquake specs
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
LCLS
Control System Testing
The SUT control system is
based on Lab View.
Here is the main operating
screen
The Epics control system
will be utilized on the Long
Term Tests
The engineering &
operating screens will be
designed and integrated
with SLAC (Stein, Xu and
Dalesio)
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
LCLS
Control System Testing
Wiring on SUT was point to point
traditionally wired. Prototype
cableway for control and monitoring
system has been developed. Locates
under Undulator Girder. Final design
is being reviewed now.
Vendor-made with standardized
connectors. >30 matching cables will
be manufactured to interconnect with
hardware e.g. motors, thermocouples,
potentiometers, BFW, etc. etc.
33 cableways needed x 30 cables
each = ~1000 cables. Installation will
be easy – commissioning will be even
easier due to ISO 9000 build and
testing.
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
Control System Testing
LCLS
Special test equipment was
constructed to aid with control
system testing.
Keyence
Inclinometer
Thermal
Vibration
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
LCLS
Mock Vacuum System Testing
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
Vacuum Chamber Adjustment Mechanism
Compound screws
- 5/8-18 screw
- 7/16-20 screw
Z-adjustment
5/16-18 screws
X-adjustment
Y Vertical Adjustment - Compound screws
5/16-18 screw
Total 26 threaded holes
14 screws for vertical adjustment
Other 12 threaded holes for lifting / adjustments
X-Z Horizontal Adjustments – Cap screws
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
LCLS
LCLS
Compound Screw Tests
Six Compound Screws Set-up (42” long)
Performed the compound screw adjustment tests (2, 6, 14 screws).
Adjustment test showed that it is possible to get fine adjustment, but it was
cumbersome to align. It also showed that the locking nut makes the process
difficult, but that it is sufficient to use. It works in both directions to adjust the
vertical height of the mockup.
A laboratory test is set-up with a single compound screw and with the proper
selection of materials, EP SST and MoS2 lub, also brass. The backlash is
small enough not to hinder micron level adjustments.
Finally, we chose 5/8-18 Brass and 7/16-20 SST compound screws to
prevent galling
Fourteen Compound Screws
Full Chamber Mock-up
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
LCLS
Lifting tests
Lifting spreader was designed to help lifting up the vacuum
chamber assembly and lifting plan was documented.
Lifting spreader was certified from the ES&H inspector after QA
inspection and static load test (500 lb).
No hazards found during the chamber installation.
12th October2006
Figure 7.
Single Undulator Test and Integration
Figure 8.
Geoff Pile
Figure 9.
pileg@aps.anl.gov
Breakdown of the spacing
between the undulator and the vacuum chamber
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
LCLS
Mock Vacuum System Testing
LCLS
Vacuum Chamber alignment
[mm]
Vertical Adjustment Screws
(14)
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
Diagnostic Systems Testing
LCLS
Ersatz Quad, Beam Position Monitor and Beam
Finder Wire alignment and positioning was
successful.
The Support and translation systems for these
items have been studied and the designs are
acceptable. All positioning and roll out specs have
been met.
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
LCLS
Assemblies and Cross Sections
Assembly
Bellows Flange
BFW Flange Seal
Locating Pins
Beam Tube Spider
Shielding Cut-out
Vacuum
Flange
Vacuum
Chamber
Flange
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
Diagnostic Systems Testing
LCLS
Beam Finder Wire
As part of the SUT, vibration tests were run on a BFW
system mock-up. The mock-up was sufficiently stable.
As part of the SUT, the mounting system for the BFW
was tested for positioning accuracy. The mount system
can locate the Chamber to within +/- 10 µm in X and Y.
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
LCLS
Kinematic Undulator Replacement
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
SUT Undulator Segment Replacement Testing
LCLS
Background:
• The Magnetic Axis of each Undulator Segment is Fiducialized to a Fixed Horizontal
and Vertical Dimension using Shim Plates Underneath and on the Ends of the
Undulator Support Plates in order to make all Undulator Segments Identical and
Interchangeable.
•
When Referenced to the Undulator Alignment Pins on the Stage Transition Plates,
Undulator Segments can be Interchanged Without the need for Realignment.
•
The Total Tolerance Budget Mandates that this Process Must be Repeatable to within
180 µm rms Horizontally and 70 µm rms Vertically*. In Reality, the Process Needs to
be Repeatable to Within a Percentage of this Tolerance to Allow for Additional
Tolerance Stack Up Elsewhere.
Purpose:
• Using only One Undulator Segment, Determine the Positioning Repeatability at
Both End of the Undulator after Removal and Reinstallation.
* From Robert Ruland’s 7/7/05 Presentation “Alignment Considerations”
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
SUT Undulator Segment Replacement Testing
LCLS
Horizontal Thick Shim
Threaded Stud Guides
Undulator Support Plate
Undulator Alignment Pins
Stage Transition Plate
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
SUT Undulator Segment Replacement Testing
Lifting/Positioning Fixture
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
LCLS
SUT Undulator Segment Replacement Testing
LCLS
August 2006 Testing Method:
• Dual Sets of Four Keyence Sensors were used to Measure the X and Y Displacement at
Both Ends of the Undulators Relative to the Girder. The “Dummy” Undulator and the Actual
Undulator had their Own Dedicated Set of Keyence Sensors so that “Zero” Positions Could
be Maintained when Switching Between the 2 Undulators
• Positions were Zeroed at the Undulator “Zero” Position. The Undulator was then Retracted
to the 80 mm Position, Unbolted and Removed from the Stages using our Lifting and
Positioning Fixtures.
• The Weight of the Undulator was Removed from the Girder using a Forklift.
• The Undulator was then Lowered to the Lifting Fixtures and Brought back Down onto the
Stages.
• Bolts were Retightened using a Torque Wrench and then the Undulator was Returned to
the Home “Zero” Position. The Keyence Sensors were Read and Recorded at this Time
and Compared with the Laser Tracker System Results.
• This Method was Repeated 4 Times for the “Dummy” Undulator and 3 Times for the Actual
Undulator.
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
SUT Undulator Segment Replacement Testing
Xupstream
Yupstream
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
LCLS
SUT Undulator Segment Replacement Testing
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
LCLS
SUT Undulator Segment Replacement Testing
LCLS
Kinematic replacement of undulator Conclusions:
• The Process of Replacing an Undulator Segment is Quick and Easy Using
the Lifting and Positioning Fixtures.
• The Process is Very Accurate and Repeatable.
• The Worst Case Repeatability for Vertical Alignment is Less than 10 Microns.
• The Worst Case Repeatability for Horizontal Alignment is Less than 40
Microns.
• The Laser Tracker Network Established around the SUT Provides Excellent
Results that are in Good Agreement with the Keyence Sensor
Measurements.
• The Laser Tracker Network will be Used Throughout SUT Testing to Provide
a Secondary Set of Measurements for Comparison to The Keyence
Sensors and Positioning Potentiometers.
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
Support/Mover System Testing
LCLS
Survey & Alignment Support:
• LEICA LTD 500 Laser Tracker System Used for System Alignment
• Local Reference Network Established with 9 Fixed Monuments Distributed
Around the SUT at Various Elevations
• Largest Measured Distance was around 3.5 m and Thus the Measurement
Accuracy was On the Order of Tens of Microns
• Mini-Monuments Used on the Girder, Undulator, and Fixed Bases for
Alignment of these Components. Tracker Also Used to Set Translation Stage
Alignment Pins
• Optical Level System Used to Align Vacuum Chamber
• Taylor-Hobson Talyvel 4 Used for System Distortion Measurements During
the Roll-Away Cycle
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
Support/Mover System Testing
Final Alignment Summary
Support Stands were set in
elevation, pitch and roll to + 0.10
mm.
The Interface Plates fell within
0.05 mm in all areas.
Final alignment of the girder was
achieved to within ±10 µm in pitch,
roll and elevation, yaw and x were
within ±40 µm.
80mm roll out tests were
successfully tracked with the laser
and compared very well against
Keyence sensor results.
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
LCLS
So how did we do? - We learned a lot!
LCLS
Support Mover (inc. fixed supports) System Testing
Initial tests were very successful – Most of the requirements have been achieved and we
learned what we had to change to meet or exceed the remaining requirements. Final
designs will incorporate all of the experience we gained and changes required to meet
these specs.
Changes include modifications to the fixed supports, girder, translation stages, wedge
blocks, cam movers and gearboxes.
Undulator Roll Out
Testing and rapid wedge block development has resolved very challenging specs that
could have been a significant problem.
Kinematic Undulator Replacement
Initial tests (dummy only) were very successful – We appeared to be well in spec but had
to complete the tests with the First Article # 1 and the dummy undulator. Final numbers
are well in spec. Making all undulator equal in production will be a relatively easy process.
Diagnostic System Testing
Initial installation, alignment and integration of ersatz BPM and BFW look very good.
Setting the stages (settability) to a “go to” position is very good.
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
Final Design enhancements
Larger clearance holes on the base plate.
More anchor points around the base
plate.
Illustration of possible mounting points. (8) total
points will be used in the final design.
Larger diameter support structure.
Standard parts will be investigated for this
improvement.
Larger threaded rods between the base
top plate and the interface plate.
Thinner grout with an improved floor
mounting method.
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
LCLS
LCLS
Design Summary
Earthquake Restraints
Cam Mounting Pads
1 ½” Interface Plate
1 ½” Top Plate
1½” Support Rod
3” Fiber Wool Insulation
(Not Shown)
1”- 8 Base Leveling /
Anchor Bolts
Stand Cap
1 ½” Bottom Plate
Support Pads
Expanding Grout
(Not Shown)
12th October2006
Single Undulator Test and Integration
Silica Sand
Geoff Pile
pileg@aps.anl.gov
LCLS
Integration
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
Integration
LCLS
Rodd Pope is talking about schedule and assembly
integration at SLAC. Here’s a different look at an
example of some of our project integration.
–verb (used with object)
in‧te‧grate ˈɪn tɪˌgreɪt
1 to make up, combine, or complete to produce a whole or a larger unit, as
parts do.
2 to bring together or incorporate (parts) into a whole.
We made up the following integration tool and are
currently developing it. It will be web accessible by
Lehman Review.
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
Integration
LCLS
We all need to ASK for information to
integrate efficiently.
This is called the ASK system.
Assembly
Sub-assembly
Kit
Example:
1. Select Support
mover on this
interactive web
page.
Support Mover box
opens up main three
areas
2. Select Fixed Support
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
Integration
LCLS
Fixed Support
Assembly.
wbs 1.04.03.08
B.O.M
A.S.K.
S.O.W
Installation info
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov
Integration
12th October2006
Single Undulator Test and Integration
LCLS
Geoff Pile
pileg@aps.anl.gov
Integration
LCLS
Microsoft Access Links –
P3 Information
PARIS Procurement info
Intralink
Free form entry allows input
from QAR CAMs & SLAC
integration engineers.
12th October2006
Single Undulator Test and Integration
Geoff Pile
pileg@aps.anl.gov