Progress on the Undulator Module System Test

1. Progress on the Undulator Module System Test Marion M. White ANL-ASD-LCLS

2. Outline • Test Scope and Deliverables • Components • Setup • Progress • Documentation, Requirements • Continued Plans • Schedule • Summary

3. Test Scope • Resolve remaining design questions on the support/mover and fixed support systems; fill in details and make improvements as needed • Provide critical input to S/M system design reviews. • Stability • Repeatability • Control and motion • Robust • Are the support/mover and fixed support systems ready for production?

4. Deliverables • Measurement of girder and rollaway motions • Precision, reproducibility, and independence of motions, including start and stop • Check for interference • Calibration • Measurement of vibration damping. • Measurement of position stability and temperature dependence of components and subcomponents.

5. Requirements • Quadrupole Motion Positioning Repeatability ±7 µm • Short-Term (1 h) BPM / Quad Stability ±2 µm • Long-Term (24 h) BPM / Quad Stability ±5 µm • Horiz. Segment Pos. Repeat. in Roll-Away Cycle ±10 µm • Vert. Segment Pos. Repeat. in Roll-Away Cycle ±5 µm • Quad Transverse Position Change in Roll-Out ±25 µm • Quad Position Reproducibility after Roll-Away Cycle ±2 µm • BPM Transverse Position Change in Roll-Out ±25 µm • BPM Position Reproducibility after Roll-Out Cycle ±2 µm

6. Goals to Demonstrate • Precision and repeatability of the cam-shaft system vertically and transversely, measured @ undulator ends, for pitch and yaw motion as well. • Goal is ± 5µ specification ± 7µ; • Precision and repeatability of 80-mm transverse travel on the linear stages. • Goal is ± 10µ • Precision of the K-value adjustment using transverse linear stages. • Goal is ± 10µ • Short term stability (10 hours) of the girder and undulator. • Goal is ± 5µ; specification ± 5µ

7. Components • Prototype undulator, or the substitute, or a 1st article if one is available and measured. • Prototype support/mover system: Girder, CAM movers, Rollaway system, controls software and hardware • Quadrupole Ersatz with fiducialization surfaces • BPM Ersatz with fiducialization surfaces • Vacuum Chamber Ersatz • WPM, HLS, BLM sensors or Ersatz • Prototype Fixed Support • Earthquake protection bracing – early prototype

8. Preparation @ ANL • Tests are done in the APS Magnet Measurement Area, MM1 • Temperature regulated • May need a plastic tent to improve thermal regulation • Clean area • Adequate space • Experienced People • Well-known floor and mechanically stable area

9. A lot of work is done • A lot of work was already done using the breadboard girder, setting up the whole system, installing and learning to use the monitoring equipment, making improvements and design modifications, and writing control and monitoring software. • The results were surprisingly good, even for the rudimentary breadboard girder, so even better performance is expected in the real prototype. • Most designs are done, and most parts are on order or in-house for the test.

10. Prototype undulator at ANL on breadboard support/mover system

11. Prototype Girder • Two rigid steel prototype girders are now being fabricated at Lynn Machine, near O’Hare airport in Chicago. • One will be used for the integrated undulator test, and the other will be used for mechanical measurements without disturbing the undulator testing activities. • The girders will be delivered to ANL by early November.

12. Improvements to the CAMs • Improvements were made to the CAMs as a result of information gained in the setup and learning phase. • Split bearing, hardness changed, spherical bearing, v-plate, more gear ratio, no brakes, …

13. Single CAM-shaft Mover • New gear box with ratio 250:1 is installed. • Calculations show this ratio is enough to hold the undulator and girder in place without a brake. • Less complexity.

14. Double CAM-shaft Mover The same changes were implemented in this unit as in the single cam-shaft.

15. Double CAM-shaft Mover (detail) Hardness of the rings on the ball-bearings was increased from 30-34 Rc to 50-55 Rc

16. Single CAM-shaft Mover working w/ “V” pad The flat pad is replaced by one with a “V” shape - 16 angle. A double bearing is installed instead of the single bearing Its purpose is to replace sliding friction by rolling friction.

17. Single CAM-shaft Mover

18. Parts in-house by end of November • Undulator substitute unit • expected 11/15 • New cam-shaft movers with new gear boxes • expected 11/25 • Modified transverse stages with 4” travel • in-house • Motors (in-house) and 90 gear boxes for stages • expected 10/31 • Transition plates, wedges and supporting parts • expected 11/25

19. Controls hardware & software • Position settability and monitoring • Verification of motion, repeatability • Verification of limits • Reproducibility and smoothness of start and stop • Temperature monitoring

20. Controls/Monitoring Working

21. Case 1: X-Translation +/- 1.5 mm Cyclic Motion Repeatability Target Repeatability < +/- 7.0 µm

22. Fixed Support • ANL assumed the Fixed Support scope: a prototype will be designed, constructed, instrumented, and ready for evaluation as a part of this test. • The FDR will address the entire support/motion system, including the fixed supports.

23. Fixed Support Design • 18” Support Tube • 1½” Support Plates • Sand Filled • 3” Wool Fiber Insulation • 1½” Anchor Bolts

24. Installation & Alignment • Design for fixed supports takes alignment and installation into account – integration of alignment philosophy with SLAC is ongoing.

25. Module Layout for Integrated Test

26. Designs are well underway: Undulator on the girder (left end)

27. Designs: undulator on the girder (right end)

28. Use Ersatz Units as Needed • The quadrupole, BPM, and vacuum chamber are fiducialized Ersatz units with the right size and weight. Some real units are planned: • Pumping crosses and pumps • Cabling, supports, and junctions • Magnet water piping • WPM, HLS, BLM sensors • Some kind of Earthquake bracing will be determined in collaboration with the SLAC safety committee, and will be incorporated; it may not be final

29. layout in short break;cartoon stages and stands

30. Earthquake bracing

31. Schedule • Design/procuring vacuum/diagnostic components • Developing detailed plan and refining engineering specifications. • Controls HW/SW demonstrated; debug/improve • Prepare/fabricate test stand and components August thru November 2005; On track to have many of the components by December 2005. • Assemble early CY-06 • Short term test March 2006; leads to FDR; with longer-term 2-month test continuing after that.

32. Schedule

33. Summary • An undulator module test will be carried out at ANL in Winter 05-06 using prototype and substitute components. • The test will provide critical data for the support/mover system final design review prior to production. • Much work was already done in Fall 05, leading to improvements in system design, choice of components, and control. • Many parts are either in-house or on order. • Controls and monitoring software was written and already demonstrated and debugged. Calibration in progress. • Remaining hardware is expected in time.