Robert Ruland
Installation Alignment -Magnetic Measurements – Fiducialization [email protected]
April 7-8, 2005 FAC Meeting 1
Installation Alignment, Magnetic Measurements and Fiducialization
Robert Ruland
Installation Alignment, Magnetic Measurements and Fiducialization
Robert Ruland
OrganizationInstallation Alignment
Error BudgetAb-initio Alignment for BBA
ConventionalGlobal Straightness
Magnetic Measurements Status of Magnetic Measurements Facility (MMF)
Location, Construction ScheduleLay-out
Test Bench Acquisition StatusTest Stands Development Status
FiducializationPointed Magnet Fixture DevelopmentCMM Acquisition Status
Monitoring Systems
OrganizationInstallation Alignment
Error BudgetAb-initio Alignment for BBA
ConventionalGlobal Straightness
Magnetic Measurements Status of Magnetic Measurements Facility (MMF)
Location, Construction ScheduleLay-out
Test Bench Acquisition StatusTest Stands Development Status
FiducializationPointed Magnet Fixture DevelopmentCMM Acquisition Status
Monitoring Systems
Robert Ruland
Installation Alignment -Magnetic Measurements – Fiducialization [email protected]
April 7-8, 2005 FAC Meeting 2
Organization
Robert Ruland
Installation Alignment -Magnetic Measurements – Fiducialization [email protected]
April 7-8, 2005 FAC Meeting 3
Undulator Alignment Tolerance
UndulatorThe measured values for Keff shall be within ± 0.0005 (i.e., ± 0.015%) of the design values(LCLS Undulator Requirements PRD 1.4 – 001)1.5*10-4 correlates to 70 µm in Y, about 180 µm in X
Quadrupoles3 µm in X and Y over ~140 mAb-initio alignment for BBA ~150 µm, desired 80 µm
Robert Ruland
Installation Alignment -Magnetic Measurements – Fiducialization [email protected]
April 7-8, 2005 FAC Meeting 4
Alignment Approach
Global alignment of 70 µm very tough
Instead will use BBA quads as alignment references for
undulator segments
Quadrupole and undulator segments are rigidly coupled by “cradle”
mounting system, undulator segments follow quads
BBA will align quad – undulator segment units to 3 µm level over
undulator system length
70 µm tolerance is “reduced” from global (~140 m length) to relative
(cradle)
Relative alignment can be done on CMM in MMF
Robert Ruland
Installation Alignment -Magnetic Measurements – Fiducialization [email protected]
April 7-8, 2005 FAC Meeting 5
Undulator – to – Quad Tolerance Budget
Vertical Horizontal [µm] [µm] Quadrupole Fiducials Pulsed Wire Center Definition 10 10 Wire to Wire Finder (WF) Fiducial 20 20 WF Fiducial to Quadrupole Fiducial 10 10 25 25 Quadrupole BBA Offset 20 20 Undulator Fiducials Hall Probe Resolution/Positioning 20 20 Needle Hall Probe Resolution 15 30 Needle Center to Fiducial 20 30 Fixture Fiducial to Undulator Fiducial 20 20 40 50 Undulator Segment Roll-Away Repeatability 5 10 Alignment Quadrupole to Undulator 40 40 Grand Total 65 70
Robert Ruland
Installation Alignment -Magnetic Measurements – Fiducialization [email protected]
April 7-8, 2005 FAC Meeting 6
Ab-initio Alignment
Conventional alignment methods, Total Station, Laser Tracker, Digital Leveling yields ~200 µmAdding additional observations should yield position uncertainty of less than 100 µm
Absolute measuring hydrostatic level measurements (ultra-sound sensor)Absolute measuring stretched wire measurements (optical wire detection)
Robert Ruland
Installation Alignment -Magnetic Measurements – Fiducialization [email protected]
April 7-8, 2005 FAC Meeting 7
Installation Alignment Workflow
Will use standard installation alignment approach. Requirement: All components use registration features to preserve pre-alignment
Install and measure alignment network
Install floor anchors and foot plates
Align foot plates to better than 0.5 mm
Install granite tables onto foot plates
Re-measure alignment network
Align undulator mechanical supports and cams of mover system
Install cradles
Install Monitoring System: HLS and WPM
Align Cradles
Straightness measurements: Alignment Stretched Wire System, Portable HLS
Align Cradles
Robert Ruland
Installation Alignment -Magnetic Measurements – Fiducialization [email protected]
April 7-8, 2005 FAC Meeting 8
LCLS Magnet Measurements 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
Construction ScheduleT1 Aug 04 (Engineering)T2 Dec 04 (Final Construction Drawings)T3 May 05 (Construction Start)Beneficial Occupancy February 2006
Robert Ruland
Installation Alignment -Magnetic Measurements – Fiducialization [email protected]
April 7-8, 2005 FAC Meeting 9
LayoutFloor plan divided into three functional areas
Magnetic Measurements (± 0.1º C)Fiducialization and Assembly (± 1º C)Storage (± 2.5º C)
Full set of specs: LCLS-TN-04-1 Z. Wolf, R. Ruland, "Requirements for the Construction of the LCLS Magnetic Measurements Laboratory“.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
Installation Alignment -Magnetic Measurements – Fiducialization [email protected]
April 7-8, 2005 FAC Meeting 10
MMF Set-up
Magnetic MeasurementsUndulator Test Bench #1 (8 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 4.5 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
Installation Alignment -Magnetic Measurements – Fiducialization [email protected]
April 7-8, 2005 FAC Meeting 11
Undulator Test Bench Status8m Magnetic Measurements Test
Bench (MMTB) Implementation ScheduleEvaluating RFP responsesAward expected for early Maydelivery to coincide with MMF
BO in Febr. 06Installation, commissioning,
MMF ready for measurements 5/30/06
Are using 5m bench obtained from APS for developing procedures and software (bench is being outfitted with equivalent hardware as 8m bench.
Will be using 5m bench for preliminary gap setting during production
Robert Ruland
Installation Alignment -Magnetic Measurements – Fiducialization [email protected]
April 7-8, 2005 FAC Meeting 12
Undulator Fiducialization & Cradle Alignment
Will use Coordinate Measurement Machine (CMM) for mechanical fiducialization measurements and alignment of components on cradle
Specs: 2µm +L/350 accuracy,4.5m x 1.2m x 1.0m volumeMin 1500kg load capacity
RFP being issued, due mid MayAward expected for early JuneDelivery to coincide with BO of MMF
Robert Ruland
Installation Alignment -Magnetic Measurements – Fiducialization [email protected]
April 7-8, 2005 FAC Meeting 13
Undulator Fiducialization Status
Proposed 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
Test measurements show an accuracy of 10 µm in X and 5 µm in Y
See LCLS-TN-05-10 Y. Levashov and Z. Wolf, “Tests of coordinate transfer from magnetic to mechanical reference for LCLS undulator fiducialization”, in preparation
Robert Ruland
Installation Alignment -Magnetic Measurements – Fiducialization [email protected]
April 7-8, 2005 FAC Meeting 14
Quadrupole Fiducialization Status
Finding the axisWill use Vibrating Wire prototype set-up. It promises better yaw and pitch resolution than pulsed wire. Implementation based on setup by Dr. Temnykh from CornellCompleted prototype setup for permanent magnets. Routinely achieved repeatabilities even in environment with wide temperature swings of better than 5 µmTest stand being re-designed for electro magnets
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
Installation Alignment -Magnetic Measurements – Fiducialization [email protected]
April 7-8, 2005 FAC Meeting 15
Integrating Monitoring Systems into Cradle / Support System
Since the cradle needs to be easily removable, we cannot attach the monitoring systems to it. Hence, both WPM and HLS need to be mounted to support table. However, the mounting has to be accomplish in a way which will force the sensors to follow the cradle motion
Robert Ruland
Installation Alignment -Magnetic Measurements – Fiducialization [email protected]
April 7-8, 2005 FAC Meeting 16
Hydrostatic Level System
3rd generation sensors with:
Improved stability
Changed interface from RS485 to TCP/IP over
10BaseT with POIP
Robert Ruland
Installation Alignment -Magnetic Measurements – Fiducialization [email protected]
April 7-8, 2005 FAC Meeting 17
HLS Stability and Resolution
Robert Ruland
Installation Alignment -Magnetic Measurements – Fiducialization [email protected]
April 7-8, 2005 FAC Meeting 18
Stretched Wire system
Robert Ruland
Installation Alignment -Magnetic Measurements – Fiducialization [email protected]
April 7-8, 2005 FAC Meeting 19
WPM Stability and Resolution
Wire System Resolution - Monitor 1 horizontal -
0.000
0.050
0.100
0.150
0:00 1:00 2:00 3:00 4:00 5:00
TimeM
on
ito
r P
osi
tio
n [
Mic
rom
eter
]
Reihe1
Linear (Reihe1)
StdDev.: = 6 Nanometer
Robert Ruland
Installation Alignment -Magnetic Measurements – Fiducialization [email protected]
April 7-8, 2005 FAC Meeting 20
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Presentation