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Undulator Magnets and Supports 20 February 2006 APS All Hands Meeting

Undulator Magnets and Supports 20 February 2006 APS All Hands Meeting. Long-Lead Procurements Titanium Strongbacks 1.04.03.03.01 Magnet Blocks 1.04.03.03.02 Magnet Poles 1.04.03.03.03 1 st -Article Undulator Assemblies 1.04.03.03.04 Single Undulator Test. Michael Bracken

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Undulator Magnets and Supports 20 February 2006 APS All Hands Meeting

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  1. Undulator Magnets and Supports20 February 2006APS All Hands Meeting • Long-Lead Procurements • Titanium Strongbacks 1.04.03.03.01 • Magnet Blocks 1.04.03.03.02 • Magnet Poles 1.04.03.03.03 • 1st-Article Undulator Assemblies 1.04.03.03.04 • Single Undulator Test

  2. Michael Bracken Loretta Cokeley Jeff Collins Alex Didenko Patric Den Hartog* Mark Erdmann Horst Friedsam Glen Lawrence Dan Nocher Tom Powers Brain Rusthoven Sushil Sharma* Emil Trakhtenberg Kurt Boerste Roger Dejus Elizabeth Moog* Shigemi Sasaki Ken Thompson Janet Werner Isaac Vasserman Dana Capatina (DD) Ron Kmak (DD) Thomas Barsz (QA) Marion White (CAM) * = Group Leader Undulator Magnets & Supports Team (significant % but none full time)

  3. LLP – Titanium Strongbacks • Require forty (40) 3.4-m-long titanium bars: Forged, annealed, vibration-stress-relieved, rough machined, vibration-stress-relieved, precision machined, inspected… • Competitively bid and awarded to two vendors to reduce risk: • Metalex [Blue Ash, OH] • Dial Machine [Rockford, IL]

  4. LLP - Titanium Strongback 1.04.03.03.01

  5. LLP – 40 Titanium Strongbacks • Total cost about 4M$ • Some growth in the raw materials cost was anticipated – but… • All material is under contract, but finding it... • 95% of titanium is used to make pigment; only about 5% is made into metal; titanium supplies are under very high pressure due to: • Civilian and military aircraft, other military applications, a very hot market in Asia…

  6. Excellent Work by Metalex – 1st Article was site-accepted by ANL on 17 October 2005

  7. Rough Machining #2 @ Metalex - 10th October

  8. 01 Feb: Metalex is ahead of schedule • S/N: 5A06990-02 Complete and Staged for Assembly • S/N: 5A06990-04 Complete and Staged for Assembly • S/N: 5A06990-06 Complete and Staged for Assembly • S/N: 5A06990-08 Complete and Staged for Assembly • S/N: 5A06990-10 Complete and Staged for Assembly • S/N: 5A06990-12 Complete and Staged for Assembly • S/N: 5A06990-14 Complete and Staged for Assembly • S/N: 5A06990-16 Complete and Staged for Assembly (The P3 date for #16 is May 24th 2006) • S/N: 5A06990-18 At machining Oper#100 • S/N: 5A06990-20 At machining Oper#100 • S/N: 5A06990-22 At machining Oper#100 • S/N: 5A06990-24 At machining Oper#100

  9. Metalex – Forging Deliveries • ATI Wah Chang plans delivery of the balance of (8) forgings to Metalex: • (4) by the end of February 2006. • (4) by the end of March 2006. • We are keeping a close eye on this, but they are so far ahead of schedule that it is unlikely to be a problem.

  10. Titanium Strongbacks – Progress@Dial 1st Article – site-accepted - 10 Nov 2005 • 10 forgings in house now. The remaining 10 are slated for shipping to Dial on Feb 20th, 2006. • Processing Strongbacks: rough machine, semi machine, drill, & tap; then inspect on the CMM before final dust mill of channel surfaces. • They will inspect, clean, deburr, and prepare for shipment; they expect to ship #3 to Hi-Tech about Feb 13th, and then about one per week for four weeks. Their bottleneck is in waiting for inspection. P3 Date Dial Date Status 07 Feb 2006 • #3 13 Jan. 2006 06 Feb. 2006 ANL Accept 07 Feb. 2006 • #5 13 Feb. 2006 10 Feb. 2006 machined, wait for insp. • #7 14 Mar. 2006 17 Feb. 2006 machined, wait for insp. • #9 12 Apr. 2006 24 Feb. 2006 machined, wait for insp.

  11. First-Article Strongback Site-Acceptance at Dial Machine, Rockford, IL – Well done !!!

  12. Titanium Strongbacks – Progress@Dial - roughing

  13. Magnet Blocks 1.04.03.03.02 • 19,200 Neodymium Iron Boron magnet blocks - about 1M$. • Magnets are fabricated in Shin-Etsu’s Takefu Plant in Japan, ground to final precise dimensions, plated for surface protection, magnetized, labeled, sorted by magnetic field, and divided into undulator-sized lots. http://www.shinetsu-rare-earth-magnet.jp/e/masspro/index.shtml details the process. • Precise sorting by magnetic field must be done, then a spreadsheet is given to the assembly vendors listing the magnet serial number and orientation for each magnet in each slot.

  14. LLP - Magnet Blocks 1.04.03.03.02 Magnetic verification of the first sample lot of magnets at APS • Initial problems • More shrinkage than anticipated • Problem with Ni plating • Magnets packed with Ink wet • All resolved • 10 sample magnets from 1st two lots were tested • Magnetic & dimensional measurements were verified. • Lots 3&4: approved to ship • Lots 5&6: samples selected and shipped to ANL • ANL magnet expert visited Shin-Etsu 24-26 Jan.

  15. 1st 2 Lots: Magnet Blocks look good Field measurement of first 10 blocks compared to the measurements from Shin-Etsu. The slight reference offset is understood. Angular direction measurement of the first 10 blocks compared to the measurements done by Shin-Etsu

  16. Schedule - Magnet Blocks 1.04.03.03.02 • The first shipment of 960 magnets, enough for both of the 1st-article undulators, finally was delivered to the assembly vendors on the 3rd of January 2006. Later than planned. • We were told to expect a faster delivery rate after the new production line, installed to meet increased global demand for these high-quality magnets, began operation in December 2005. • Met with Shin-Etsu 17 January 2006 @ANL.

  17. Magnets received at Metalex 3rd January

  18. Our needs are met by Shin-Etsu’s Re-Commitment dated 19 Jan 2006:

  19. LLP - Magnet Poles 1.04.03.03.03 • 19,200 vanadium permendur magnet poles. • The material is forged into rectangular bars and annealed for ductility [www.vacuumschmelze.com], then sawed into slices, milled, ground, lapped to the precise dimensions, and finally annealed for best magnetic performance. • 49% cobalt, 49% iron, 2% vanadium

  20. LLP Scope: Magnet Poles 1.04.03.03.03 (2) • Awarded to Hi-Tech Manufacturing, Schiller Park, IL [near O’Hare Airport]. • Award value: about 1M$ • Major simplification of the pole design, eliminating titanium wings, saved a lot. • Vendor has made similar items for APS. • Understands the job and has developed special tooling and processes for working with this tricky material.

  21. Magnet Poles – Progress @ Hi-Tech • Raw material is in house. • 1st 1000 poles, enough for the 2 first-article undulators plus spares, were complete, inspected, and ready for delivery the week of November 7th; • Hi-Tech procured a new CMM to enable automatic inspection of the 19200 poles. • Poles are ahead of the required schedule.

  22. Pole Mfg/Shipping Summary • Poles Sent To Metalex 50% of their needs • 5000 Pieces L143-110105-03 (undulators 2, 4, 6,8,10,12,14,16,18,20) • 85 Pieces L143-110107-02 • Completed For Hi-tech • 1000 Pieces L143-110105-03 (undulators 1 and 3) • 10 Pieces L143-110107-02 • Next Lot For Hi-tech (Ready By Mid-February) • 4000 Pieces L143-110105-03 (undulators 5,7,9,11,13,15,17,19) • 75 Pieces L143-110107-02 • Total Machined 13,000 Pieces

  23. Poles – example of inspection report

  24. Magnet Poles – Mfg. Progress @ Hi-Tech Staged for Assy.

  25. 1st Article Undulator Assemblies Prototype undulator (now @SLAC) on a simple breadboard girder used to gain experience with CAM mover control and monitoring @ANL.

  26. LLP – 1st-Article Undulator Assembly • First-article assembly awards were made to two vendors, with options for more pending 1st-article acceptance, available BA, and arrival of actual money at ANL. • Very favorable assembly costs; significant savings: • Two 1st articles • Series of 38 • The design, intellectual development, and prototyping were completely done by ANL, thus we could utilize precision machine shops instead of special-purpose magnet firms for the assembly. The budgeted amounts were based on past history with magnet specialists. • Intensive value engineering efforts and assembly planning contributed greatly to the savings.

  27. 1st-Article Undulator Assembly - Two Awards: • Metalex - Blue Ash, OH • Making ½ of the strongbacks • Excellent vendor • Saves on shipping • Hi-Tech - Schiller Park, IL • Making all of the poles • Performed many jobs for APS in the past • Saves on shipping

  28. ES&H and Informational Visit • Representatives of both undulator assembly vendors visited the APS in October 2005 in order to see the prototype undulator before it was shipped to SLAC. • They gained valuable experience in safe handling of these extremely strong magnets, and were able to practice a little bit in preparation for assembly at their facilities.

  29. QA & Vendor Management • The APS undulator experts responsible for design, construction, assessment, and value engineering of the prototype undulator, are responsible to oversee the undulator magnet and support procurements. • Responsibility for vendor management, vendor oversight and performance, and undulator performance rests with ANL-APS.

  30. Vendor relations and management are critical. If you start off right, chances for success are far better. Even a superb vendor may need some prodding to get in tune with the program. Incorporate QA from the start; pay attention to the details; work together with the vendors and keep procurement involved.

  31. Assembly Progress @ Hi-Tech • Hi-Tech has received all long lead items (LLP) required for its 1st article. • The assembly area as well as all required documentation deliverables, such as work plans, are ready. • Hi-Tech is 100% complete with non-LLP components and has started 1st-article undulator assembly.

  32. The Plan: Assembly – short base

  33. Assembly – short base with poles

  34. Assembly – short base - fully assembled with poles, magnets, and clamps

  35. Assembly – short base – fixture for precision positioning of the first poles

  36. Assembly – Use the transfer fixture for precision positioning of the next poles; anchor with four poles

  37. Assembly – continue down the line

  38. Assembly – completed long base

  39. Poles are inserted into the long base using the precision fixture designed by ANL. The four end poles are used as a locating reference for the next group. The fixture that enables safe joining of the top and bottom is also ready. Insert Poles into Base; Joining Fixture @Hi-Tech

  40. Poles assembled into bases, being readied for insertion of magnets and then assembly into the strongback. Hi-Tech 06 Feb 2006

  41. Magnets are labeled and arranged according to our sorting list; Red on top, Green on the bottom Assembly Progress at Hi-Tech (07Feb06)

  42. Assembly Progress @ Metalex • All documentation received: • Program Plan • Inspection and Test Planning • Quality Verification Plan • Program Schedule • Raw Materials are delivered. • The assembly area dedicated to this project is prepared. All work benches, storage racks, overhead cranes, and special tools are ready. • Parts are 100% ready.

  43. Assembly Progress @Metalex: Short Bases

  44. Assembly Progress @Metalex: Inspection of Short Base

  45. Assembly Progress atMetalexLong Bases

  46. Assembly Progress @Metalex: Clamps and Travelers

  47. Non-Magnetic Tools @ Metalex

  48. Assembly Area @Metalex – huge clean space – plenty of room for other things {ILC???}

  49. 1st Article Assembly/Tuning Schedule UN33_40060 AWARD: 1st Art Mag Assy - Hi-Tech 1 25-Oct-05 UN33_40100 Hi-Tech Procure - 1st Art Mag Assy Parts 42 10-Nov-05 19-Jan-06 UN33_40110 RCV: Ti S/B Article 01, Blocks, Poles, Parts 0 03-Jan-06 UN33_40120 Hi-Tech Fab/Assy-Mag Article 01 Assembly 42 20-Jan-06 20-Mar-06 UN33_40122 Review Hi-Tech travelers/data 2 21-Mar-06 22-Mar-06 UN33_40124 Factory Acceptance Article 01 - Hi-Tech 2 23-Mar-06 24-Mar-06 UN33_40128 Hi-Tech Undulator Article 01 Ship to ANL 1 28-Mar-06 UN33_40140 RCV: From Hi-Tech - Magnet Assy #1 1 29-Mar-06 UN33_00530 Mag Meas & Tune-Hi-Tech Article 01 21 30-Mar-06 27-Apr-06 UN33_00550 ACCEPT: Hi-Tech Und Article 01 @ANL 5 28-Apr-06 04-May-06 UN33_00554 ACCEPT: Hi-Tech Und Article 01 @SLAC 0 18-May-06 UN33_40150 AWARD: 1st Art Mag Assy - Metalex 1 26-Oct-05 UN33_40190 Metalex Procure - 1st Art Mag Assy Parts 42 15-Nov-05 24-Jan-06 UN33_40200 RCV: Ti S/B Article 02, Blocks, Poles, Parts 0 03-Jan-06 UN33_40210 Metalex Fab/Assy-Mag Article 02 Assembly 42 25-Jan-06 23-Mar-06 UN33_40211 Review Metalex travelers/data 2 24-Mar-06 27-Mar-06 UN33_40212 Factory Acceptance Article 02 - Metalex 2 28-Mar-06 29-Mar-06 UN33_40214 Metalex Undulator Article 02 Ship to ANL 5 31-Mar-06 06-Apr-06 UN33_40220 RCV: From Metalex - Magnet Assy #2 1 07-Apr-06 UN33_00560 Mag Measure & Tune-Metalex Article 02 21 28-Apr-06 26-May-06 UN33_00580 ACCEPT: Metalex Und Article 02 @ANL 5 30-May-06 05-Jun-06 UN33_00620 ACCEPT: Metalex Und Article 02 @SLAC 0 19-Jun-06

  50. Single Undulator Test • Prototype Fixed Supports • Prototype Girder and Motion System • Prototype or 1st-article Undulator • Controls software and hardware for readout, monitoring, and motion control. • Vacuum chamber prototype (solid) • Quadrupole Ersatz • BPM prototype • All other components on the girder or in the break sections will be represented by actuals or Ersatz.

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