Measurement report of Boostec girders 1/13 Sylvain GRIFFET, 15/11/2010 Measurements performed on the...

Measurement report of Boostec girders

1/13Sylvain GRIFFET, 15/11/2010

Measurements performed on the 28th of October 2010 with the Laser Tracker LTD500

EDMS n°1103378

Plan

INTRODUCTION

Tolerances to be checked

Coordinates system

Summary3079 girder3069 girder

CONCLUSION


Sylvain GRIFFET, 15/11/2010 2/13

INTRODUCTION

The objective of the measurements is to perform the dimensional control of the 2 Boostec girders on site before receipt at CERN. We measured this girders according to Nicolas Chritin plans and tolerances (EDMS n° 1098660) using the Laser Tracker Leica LTD500.Measurement conditions were good: temperature stability of 20.5°C to 20.8°C during the day.We will present measurement results with an accuracy of about 10 µm rms for the flatness and coaxiality and of about 20 µm rms for the positioning.






ReferenceA

ReferenceD

ReferenceE

ReferenceC

ReferenceB

ReferenceF (Idem B)

ReferenceG

ReferenceH

ReferenceI

ReferenceA

REFERENCE A

POSITIONING319 mm

PERPENDICULARITY

PERPENDICULARITY

PERPENDICULARITY

PERPENDICULARITY

POSITIONING529 mm

ReferenceD

POSITIONING210 mm

PERPENDICULARITY

PERPENDICULARITY

ReferenceE REFERENCE E

POSITIONING1946 mm*

PARALLELISM

PERPENDICULARITY

PERPENDICULARITY

ReferenceC REFERENCE C PERPENDICU

LARITYPERPENDICU

LARITY

ReferenceB

MEDIAN PLAN

65+65 mm

POSITIONING65 mm

ReferenceF (idem B)

MEDIAN PLAN

65+65 mm

POSITIONING65 mm

ReferenceG AXIS POSITIONING

65 mmPOSITIONING

65 mm

PLANEITYOR

COAXIALITYYES YES YES YES YES YES

General tolerances of ± 0.01 mm, *Tolerances of ± 0.1 mm







Coordinates system

In a first time: _ Y axis = mean cylinders axis_ Z axis = perpendicular to the mean plan A_ System origin O = intersection of Y with the mean plan C

However: _ The cylinder diameter is not exactly 120 mm long but 119.55 mm (LTD measurement)

After checking of the V-supports geometry, the following coordinate system was chosen:_ Y axis = mean cylinders axis corrected by the offset of √2*Δφ/2, so 0.318 mm_ Z axis = perpendicular to the mean plan A_ System origin O = intersection of Y with the mean plan C



Summary



3079 girder

•The only significant flatness faults for the 3079 girder are the following:Definition of the upper plan D global: 15 µm rms. This fault has no impact because of the choice of the independent DBQ adjustment. The local fault on the D plan on the girder centre: 49 µm rms, range of -210.247 mm to -209.882 mm. The concerning location is not essential to the DBQ adjustment.

Summary



3079 girder

•Positioning fault: The side plan F, B, H and I are not correctly located with respect to the median plan: offsets of the order of 0.15 mm whereas the tolerance is ± 10 µm. We propose that Boostec will machine the girder where there is too much material and for our part, we will define shims from CMM measurements to wedge where there is a lack of material.

3079 girder

The location of the D(entry) plan with respect to the beam axis is -209.914 mm instead of -210 mm. There is no impact because of the DBQ adjustment.The distance between the lower plan A and the beam axis is too short of about 30 µm. The CMM measurement will permit to determinate with a better accuracy this fault and its impact.

•No problem of perpendicularity.

Summary



Summary



3069 girder

•The only significant flatness faults for the 3069 girder are the following:Definition of the upper plan D global: 19 µm rms. Like for the first girder this fault has no impact. The local fault on the D plan on the girder centre: 43 µm rms, range of -210.163 mm to -209.859 mm. The concerning location is not essential to the DBQ adjustment.

Summary



3069 girder

•Positioning fault: The side plan F, B, H and I are not correctly located with respect to the median plan: offsets of the order of 0.10 mm whereas the tolerance is ± 10 µm. In addition the girder is too narrow of approximately 50 µm. We propose the same solution as for the first girder : machining by Boostec and wedging by CERN.The location of plans D, entry and exit, with respect to the beam axis are respectively -209.915 mm and -210.056m instead of -210 mm. There is no impact because of the DBQ adjustment.

•No problem of perpendicularity.

CONCLUSION

According to the results and accuracy of LTD500, we can say that the Boostec girders don’t respect all the tolerances defined by Nicolas Chritin. The positioning faults seem to come from a mistake on the drawings instead of a lack of know-how

However, following the «Dimensional control and fiducialisation » meeting of November the 9th, we think it will be possible to correct the faults if the girders are machined on the side plans.

These corrections are possible because there are only two Boostec girders, but for the future of CLIC, when we speak of thousands of modules, it will be necessary to better translate our expectations into drawings.



Flatness and coaxiality

3079 girder

_ Plans flatness : A : 9 µm rmsD (entry) : 9 µm rmsD (exit) : 10 µm rmsD global (entry + exit) : 15 µmE : 2 µm rmsC : 7 µm rmsBg : 5 µm rmsBd : 5 µm rmsFg : 9 µm rmsFd : 2 µm rmsH : 8 µm rmsI : 4 µm rmsFor all plans, the measurement flatness is of the order of the LTD accuracy, except for the D global plan.In addition, there is a local fault on the D (entry) plan, located on the solder, at the center of the girder: flatness of 49 µm rms._ Axis coaxiality for the cylinder locations: 10 µm RMS


Sylvain GRIFFET, 15/11/2010

Supplementary Slide

Flatness and coaxiality

3069 girder

_ Plans flatness : A : 13 µm rmsD (entry) : 7 µm rmsD (exit) : 8 µm rmsD global (entry + exit) : 19 µmE : 2 µm rmsC : 7 µm rmsBg : 6 µm rmsBd : 7 µm rmsFg : 10 µm rmsFd : 1 µm rmsH : 8 µm rmsI : 4 µm rmsFor all plans, the measurement flatness is of the order of the LTD accuracy, except for the D global plan.In addition, there is a local fault on the D (entry) plan, located on the solder, at the center of the girder: flatness of 43 µm rms._ Axis coaxiality for the cylinder locations: 10 µm RMS



Supplementary Slide

Positioning

3079 girder

_ Positioning of C with respect to E (along Y), distance between mean plans : 1946.089 mm or 89 µm of offset with respect to the nominal length.

_ Positioning of A with respect to Y axis (along Z): distance from the mean plan A to the Y axis of 28.972 mm or an offset of 28 µm.

_ Positioning of Bg with respect to the median plan: -64.823 mm instead of -65 mmPositioning of Bd with respect to the median plan:65.157 mm pour 65 mmPositioning of Fg with respect to the median plan: -64.856 instead of -65 mmPositioning of Fd with respect to the median plan: 65.130 mm instead of 65 mmThe girder width is good but the distances to the median plan are not respected.



Supplementary Slide

Positioning

3079 girder

_ Positioning of D plans:D(entry) without fault: -209.914 mm instead of -210 mm, or an offset of 86 µm.D(entry), on the fault location, is located between a lower plan at -210.247 mm and an upper plan at -209.882 mm. the fault does not exceed the girder.D(exit): -210.008 mm instead of 210 mm

_ Positioning of H with respect to Y axis (along X): 65.154 mm instead of 65 mm

_ Positioning of I with respect to Y axis (along X): 65.153 instead of 65 mm

H and I are consistent with the Bd and Fd plans: there is an offset of +0.15 mm with respect to the median plan.



Supplementary Slide

Positioning

3069 girder

_ Positioning of C with respect to E (along Y), distance between mean plans : 1946.075 mm or 75 µm of offset with respect to the nominal length.

_ Positioning of A with respect to Y axis (along Z): distance from the mean plan A to the Y axis of 528.982 mm, or an offset of 8 µm.

_ Positioning of Bg with respect to the median plan: -65.04 mm instead of -65 mmPositioning of Bd with respect to the median plan: 64.906 mm instead of 65 mmPositioning of Fg with respect to the median plan: -65.088 mm instead of -65 mmPositioning of Fd with respect to the median plan: 64.865 mm instead of 65 mmThe girder is too narrow of approximately 50 µm and the distances to the median plan are not respected.



Supplementary Slide

Positioning

3069 girder

_ Positioning of D plans:D(entry) without fault: -209.915 mm instead of -210 mm, or an offset of 85 µm.D(entry), on the fault location, is located between a lower plan at -210.163 mm and an upper plan at -209.859 mm. the fault does not exceed the girder.D(exit): -210.056 mm instead of -210 mm

_ Positioning of H with respect Y axis (along X): 64.898 mm

_ Positioning of I with respect to Y axis (along X): 64.891 mm

H and I are consistent with the Bd and Fd plans: there is an offset of -0.1 mm with respect to the median plan.



Supplementary Slide

Perpendicularity



3079 girder

E with respect to A: offset of 10 µrad or 3 µm at 32 cmC with respect to A: offset of -49 µrad or 16 µm at 32 cmBg with respect to A: offset of -346 µrad or 7 µm at 2 cmBd with respect to A: offset of 361 µrad or 7 µm at 2 cmFg with respect to A: offset of 227 µrad or 5 µm at 2 cmFd with respect to A: offset of 438 µrad or 9 µm at 2 cmH with respect to D (exit): offset of 1203 µrad or 24 µm at 2 cmI with respect to D (entry): offset of -438 µrad or 9 µm at 2 cm

Supplementary Slide

Perpendicularity



3079 girder

Bg with respect to E: offset of -56 µrad or 3 µm at 5 cmBd with respect to E: offset of -89 µrad or 5 µm at 5 cmFg with respect to C: offset of -112 µrad or 6 µm at 5 cmFd with respect to C: offset of 24 µrad or 1 µm at 5 cmC with respect to Y axis (around X): offset of -54 µrad or 17 µm at 32 cmC with respect to Y axis (around Z): offset of -51 µrad or 7 µm at 13 cmE with respect to Y axis (around X): offset of 19 µrad or 6 µm at 32 cmE with respect to Y axis (around Z): offset of 14 µrad or 2 µm at 13 cm

Supplementary Slide

Perpendicularity



3069 girder

E with respect to A: offset of -33 µrad or 11 µm at 32 cmC with respect to A: offset of -5 µrad or 2 µm at 32 cmBg with respect to A: offset of -602 µrad or 12 µm at 2 cmBd with respect to A: offset of -335 µrad or 7 µm at 2 cmFg with respect to A: offset of 377 µrad or 8 µm at 2 cmFd with respect to A: offset of 473 µrad or 10 µm at 2 cmH with respect to D (exit): offset of 24 µrad or 1 µm at 2 cmI with respect to D (entry): offset of 679 µrad or 14 µm at 2 cm

Supplementary Slide

Perpendicularity



3069 girder

Bg with respect to E: offset of 31 µrad or 2 µm at 5 cmBd with respect to E: offset of -61 µrad or 3 µm at 5 cmFg with respect to C : offset of -220 µrad or 11 µm at 5 cmFd with respect to C : offset of -23 µrad or 1 µm at 5 cmC with respect to Y axis (around X) : offset of -57 µrad or 18 µm at 32 cmC with respect to Y axis (around Z) : offset of -2 µrad or 0.3 µm at 13 cmE with respect to Y axis (around X) : offset of 43 µrad or 14 µm at 32 cmE with respect to Y axis (around Z) : offset of -35 µrad or 5 µm at 13 cm

Supplementary Slide

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Measurement report of Boostec girders 1/13 Sylvain GRIFFET, 15/11/2010 Measurements performed on the...

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