Beam Finder Wire (BFW) Status

1. Beam Finder Wire (BFW)Status Jim Bailey

2. Introduction • BFW Purpose • Locate the center line of the Undulator relative to the electron beam • BFW Function • Located upstream of each Undulator Segment • Fiducialized so that its horizontal and vertical wires have a fixed and known locations with respect to Undulator center line (girder axis)

3. Introduction Con’t • Wires are brought into collision with the electron beam by movement of the Undulator Segment • Amount of beam striking the wires are measured via beam induced current in the wires • Or by detection of scattered particles down stream • Relative position of beam and undulator is determined by the above measurements • Wires are removed from the beam path

4. BFW In Situ- Short Break BFW Undulator Undulator Beam Girder Girder

5. Physics Related Engineering Requirements • One Vertical and One Horizontal Wire • Independent Signal from Each Wire • 0.030 – 0.040 mm Diameter Carbon Fiber • Remotely Removal from Beam Path • Hardware Clearance Radius at Target >2mm

6. Physics Related Engr. Req’ts. (Cont’d) • Wire Positioning • Perpendicularity 10 mrad • Roll, Pitch, Yaw 10 mrad (10mrad: 0.01”/1”) • Y-Wire Reproducibility 30µm • X-Wire Reproducibility 80µm • Measured Position of Wires Relative to External Fiducial to be within 30µm • Provide Adjustment per Above • Location Tolerance (Implied) +/- 0.050 mm

7. BFW Assembly Mounted on Adjustable Support Electrical Connectors for Wire Signals Potentiometer Pneumatic Solenoid Valve Compression Spring Positioner Air Supply Shut Off Valve Precision Screw Card Position Monitor (Limit switches) Frame Housing Alignment Fiducials Pneumatic Cylinder Vacuum Pump Connector (2.75” Conflat Flange) Vacuum Chamber Connection Flange (NW-50 CeFix w/Clamp) Adjustable Mounting Support Beam Port

8. BFW Assembly (Body Sectioned) Wire Card Down in Inactive Mode Potentiometer (Out Position) Electrical Connectors (Down Position) Internal Return Spring (Expanded Position) Internal Kinematic Stop Plates (Open Position) Pneumatic Solenoid Valve (Cylinder Vent Position) Lower Limit Switch (Actuated Position) Bellows Seal (Compressed Position) Wire card (Down Position) BEAM

9. BFW Assembly (Body Sectioned) Wire Card Up in Active Mode Potentiometer (In Position) Electrical Connectors (Up Position) Internal Return Spring (Compressed Position) Internal Kinematic Stop Plates (Closed Position) Pneumatic Solenoid Valve (Cylinder Pressurized Position) Bellows Seal (Expanded Position) Upper Limit Switch (Actuated Position) Wire card (Up Position) BEAM

10. Moving Slide Assembly (Solid Body) Electrical Connector and Feedthrough Secured to Slide Rod Kinematic Stop Top Plate Fixed to Frame (Adjustable using precision Screws) Top of Return Spring Fixed to Frame Kinematic Stop Bottom Plate Secured to Slide Block Slide Block Secured to Slide Rod Cylinder Bore Fixed to Frame Card Mount Block Secured to Slide Rod

11. How Kinematic Plate Adjustment Works Locking Screw with Lock Washer Precision Screws Precision Screw Spring Loaded Positioner Clearance between slide rod and frame Top Kinematic Plate attached to Frame Frame

12. Wire Card in Situ (Active Mode) Note: * Signal Conductor and Insulating beads pass through center hole in the Slide Rod Slide Rod* Card Mounting Block Vacuum Seal Gasket Ceramic Insulating Beads (TYP)* Mounting Screw (TYP) Locking Collar Winding Pin (TYP) Signal Conductor (TYP)* Ceramic card Wire Tensioner (TYP) Vertical Carbon Wire (This Side of Card) Horizontal Carbon Wire (Other Side of Card)

13. BFW Prototype Setup “Keyence” Sensors Supports Read Out Precision Screws Kinematic Stop Plates Engaged Vacuum Line Fixed Frame Movable Assembly Air Supply Line 70 psi Pneumatic Cylinder Vacuum Chamber Bellows

14. BFW Prototype Setup Locking Screws w/ lock washer Fixed Bottom Plate Movable Assembly Locking Collar Bellows Extended Precision Screws in Top Fixed Plate

15. BFW Prototype Setup Spring Loaded Positioner Precision Screw-Horizontal Adj.

16. BFW Prototype Results • Vertical Repeatability: +/-7 Microns • Horizontal Repeatability: +/- 14 Microns (Extrapolated to account for lever arm) • Adjustability: +/- 2 Microns • Required Force on Kinematic Stop: 20 lbs. • Slide Rod Clearance: 0.020” • Top Locking Screws: Lock Washers OK

17. Bench Adjustment (Initial and Replacement) Slide Fiducials Vertical and Horizontal Adjustment Screws Flange Locating Pins Supply Air to Actuate Cylinder Bench Fiducials Wire Card Fiducials (Not Shown) Adjustment Bench located on CMM Beam Center Line Based on Bench Fiducials

18. Installation and Replacement Alignment Strategy BFW Fiducials BFW Fiducials Undulator Fiducial Surface and Mount Hole Undulator Side Fiducial

19. Alignment Accuracy byGeorg GassnerGraphical output of the SIMS simulation (front view)

20. Alignment Accuracy byGeorg Gassner The alignment of the BFW in relation to the undulator segment is achievable with the given tolerances.The requirements given for the grand total uncertainty between the actual position of the so called “loose end” to the nominal position is 80 micrometers vertically and 140 micrometers horizontally (see PRD 1.4-004-r1). In the case of the BFW, this number includes the uncertainty of the undulator fiducialization, BFW fiducialization wire positioning repeatability, CAM positioning repeatability, Undulator segment roll away repeatability and alignment of the BFW to the Undulator. To get a better idea of the real numbers we did a simulation of the alignment parts, optical CMM (20 micrometer accuracy) and mechanical CMM (10 micrometer accuracy) with an alignment analysis simulation software package (SIMS 3.6). The calculated uncertainty is 28 micrometers vertically and 40 horizontally for the CMM parts and results in a grand total accuracy of 60 micrometers vertical and 100 micrometers horizontal (1 sigma). For the calculation only random errors are considered, biased measurements will affect the results further. The main error sources remaining are the wire repeatability (30 mm / 80 mm) and the undulator fiducialization (40 mm / 50 mm).

21. Design Parameters • Required actuating force: Slide Weight (11 lbs) + Vac. (15 lbs) + Bellows Spring (7 lbs) + Return Spring (15 lbs) + Stop (20 lbs) = 68 lbs • Available Cylinder Force at 90 psi = 81 lbs • Thermal Expansion Ref. For 304 SS at 10 in. (254 mm) height above girder exp. = 4.5 µm/C

22. Electrically Controlled Solenoid Valve Wire Signal Connector Interfaces Potentiometer Limit Switches Bellows Flange Instrument Air Supply Undulator Fiducials Vacuum System (Vents Vacuum Chamber) Undulator Flange Support Beam Loss Monitors Girder

23. Final Design Review • Held September 20, 2006 • Significant issues of the design that were reviewed include: • Design meets the requirements of the PRD and the ESD, • Responses to preliminary design review comments, • Reliability and practicality of the mechanical design, • Wire card design, • Fabrication and assembly considerations, • Material selection, • Vacuum compatibility, • Alignment strategy (initial and replacement), • Accuracy and repeatability of the wire placement (Review of prototype results), • Environment considerations, • Interfaces with adjacent components and systems, • Control and monitoring requirements, • Maintenance and wire replacement, • Safety • Reviewed approved fabrication drawing

24. Final Design Review Committee Report • Recommendations: The ANL/SLAC team should proceed with the fabrication of the Beam Finder Wire Assembly and the BFW Support Assembly excluding the Wire Card Assembly. The Wire Card Assembly should have a design review after final material selections are complete. • Transmittal Comment from FDR Chairman:  ”The design team including the SLAC participants has done an excellent job on this hardware design.  The prototyping effort is particularly appreciated.  I am certain that the beam finder wire assembly will be successful.”

25. Conclusions • Open Items • Need to modify the wire card design to accommodate carbon fiber wires. • Need to incorporate suggested dimensioning comments and other drawing markups that were provided by the FDR committee. • Design Status: • After incorporation of final design review comments the design will be ready for the procurement process.

26. Conclusions Con’t • Near Term Schedule • Prepare procurement packages by 11/1/06 • Place orders and award contracts by 12/1/06 • Prepare assembly, test and alignment procedures by 3/1/07 • Design and fabricate fixtures for above procedures by 3/1/07 • Receive all parts by 3/1/07 • Assemble, align, test and ship first three articles by 4/1/07

27. Conclusions Con’t Project Schedule