Senior Operations Technician Development of a Remotely Controlled, Mobile, Thermal Imaging Platform. Adrian Johnson Senior Operations Technician Diamond Light Source Adrian Johnson. ARW2011 10-15 April 2011

Overview of Diamond Opened for Users in 2007. Currently 18 operational Beamlines. 4 Beamlines currently under construction. Total of 32 Beamlines by 2017. Adrian Johnson. ARW2011 10-15 April 2011

Overview of Diamond Accelerators 100MeV Linac. 3GeV Booster. 3GeV Storage Ring. Stored Beam currently at 200mA (running in Top up). Target of 300mA (running in Top up). Stable beam to provide steady conditions for Users. Beam position to be stable and reproducible. Beam profile to stable and reproducible. Minimise beam downtime. Adrian Johnson. ARW2011 10-15 April 2011

The Need Assessment of beam induced heating. Assessed by calculation, but needs verifying. Entry with handheld camera after beam dropped not adequate. As we head towards 300mA beam, want to perform thermal surveys of the Storage Ring with stored beam present. To do this needs a remote control thermal imaging camera. Adrian Johnson. ARW2011 10-15 April 2011

The Working Environment Inside the ‘Locked up’ Vaults. Stored Beam present. Blue lighting. Smooth Flooring. Few obstacles. Trenches. Adrian Johnson. ARW2011 10-15 April 2011

The Working Environment Accelerator vaults divided into PSS search Zones. Zone gates at either end and on entrance. Zone gates are interlocked. Traps remote control camera in one Zone. Access only during Machine Development shifts. Adrian Johnson. ARW2011 10-15 April 2011

Design Requirements Capable of capturing Thermal Images. Capable of being fielded in the Accelerator Vaults with beam present. Without affecting the machine operation. Remotely Controlled from the Control Room. Stable and Controllable. Able to recharge batteries to facilitate long term use. Locked in a zone for at least 1 week. Inexpensive. Height Adjustment on Thermal Camera. Adrian Johnson. ARW2011 10-15 April 2011

Hardware Thermal Camera FLIR A320 Pan / Tilt Head Visible light Camera Motorised Lab Jack CoroBot ‘Robotic’ Drive unit Adrian Johnson. ARW2011 10-15 April 2011

Network set up Camera Platform controlled over a Wireless network. FLIR and Axis cameras connected to CoroBot LAN port via a Network switch. CoroBot LAN and WiFi connected via ‘Network Bridge’ in Windows XP. Wireless access point connected to existing ‘secondary’ network in Vault. Adrian Johnson. ARW2011 10-15 April 2011

Software Control Software. Microsoft Robotics Studio, written in C#. Modular Services running concurrently (i.e. each one on a separate thread). Services read from sensors or sends commands to actuators or read/write to other services. Control by communication between services. Used original CoroBot Drive, Motor Encoder control and Input / Output Board Services. New Services written: Motor Control Board (to control Height adjustment motor). Robot Drive Control. Robot Power. Adrian Johnson. ARW2011 10-15 April 2011

Battery charging Modifications for Battery Charging. Adrian Johnson. ARW2011 10-15 April 2011

Height Adjustment Addition of Camera Height adjustment. Speed controlled to accelerate / decelerate smoothly, to prevent tipping. 25cm (40cm full travel) of height adjustment, to put Thermal Camera 1m from floor level. Adrian Johnson. ARW2011 10-15 April 2011

Control Controlled from the Main Control Room. Driven by the on duty Operator. Two Remote desktop sessions. 1st to the Robot PC. Control GUIs for Driving, Battery Charging and Pan/Tilt head. 2nd to another Windows PC. FLIR camera software. Axis Camera web page (used for Navigation). Can also be controlled from any PC/Laptop connected to the Network. Adrian Johnson. ARW2011 10-15 April 2011

Control User Interfaces Adrian Johnson. ARW2011 10-15 April 2011

Usage. Storage Ring Survey. 2010. Nov / Dec 2009 – started survey 250 & 275mA stored beam. High current running and surveys being carried out during Machine Development shifts. Two Zones completed. High current running delayed due to RF cavity issues. 2010. Verification of correct water flow to Booster RF Cavity following adjustment and manifold modifications. Confirmation that a set of Vacuum bellows was not damaged following a Girder movement. Monitoring of new components installed, during a major lattice change. Adrian Johnson. ARW2011 10-15 April 2011

Vacuum Vessel Bellows - Results RF Off RF On 50kW CW 200mA 900 bunches 150mA 600 bunches Adrian Johnson. ARW2011 10-15 April 2011

New Installation - Results RF Off 200mA 900 bunches 200mA hybrid fill Adrian Johnson. ARW2011 10-15 April 2011

New Installation - Results RF Off 200mA 900 bunches 200mA hybrid fill Adrian Johnson. ARW2011 10-15 April 2011

Networking Components Costs Item Cost (as of 2009) FLIR A320 Thermal Camera £7500 CoroBot £3000 Axis 213 Camera £1400 Pan / tilt head £130 Motor Control Card £100 Modified Lab Jack £150 Networking Components £50 Misc. £200 Total £12530 Estimated ½ man year of effort from concept to use. Adrian Johnson. ARW2011 10-15 April 2011

Limitations Limitations. The platform can only be used in one PSS zone at a time, due to the Zone Gates. Viewing of components on the ‘far side’ of the Storage Ring is limited to static placement. Battery life when roaming, approx. 1 hour. Radiation damage to the Axis camera. Battery life degradation. Adrian Johnson. ARW2011 10-15 April 2011

Summary An inexpensive Remote Control, Mobile, Thermal imaging camera platform has been developed. It has been in use in the Diamond accelerator vaults, with beam present, for over a year. It has proved to be a useful tool. Adrian Johnson. ARW2011 10-15 April 2011

End of Presentation Adrian Johnson. ARW2011 10-15 April 2011

Hardware Details (appendix) FLIR A320 Thermal Camera. 320x240 pixel, uncooled microbolometer. -20ºC to +120ºC or 0ºC to +350ºC temperature range, ± 2ºC accuracy. TCP/IP communication. Hague Pan/tilt camera mount. USB controlled. CoroBot ‘robotic’ drive unit. 1.5GHz PC, 512MB RAM, 802.1g WiFi card, 80GB Hard drive, Windows XP. 4 wheel motorised drive, with differential speed steering controlled via a Lynx motion SSC-23 servo control board. A Phidgets 8/8/8 Interface card to provide 8 Analogue and 8 Digital inputs and 8 Digital Outputs. 10AHr 12V rechargeable batteries, ~2.5hours of run time. Axis 213 PTZ camera. TCP/IP camera. ±170º Pan, -10º to +90º tilt. Low Light mode, with built in Infra Red LED light. Adrian Johnson. ARW2011 10-15 April 2011

Timescales (appendix) Oct 2008 - Project initiated. Dec 2008 – Specification issued. Jan 2009 – Orders placed. Apr 2009 – All Hardware delivered. June 2009 – First test fielding in Linac (no charging). Hardware and Software Modifications made to facilitate charging. Nov & Dec 2009 - Survey of Storage Ring started, 250 and 275mA stored beam. High current running and surveys being carried out during Machine Development shifts. High current running delayed due to RF cavity issues. Adrian Johnson. ARW2011 10-15 April 2011

Timescales (appendix) Jan to May 2010 – Modifying Robot to fit Height adjustment and write software. Jun 2010 – Monitoring of Booster RF Cavity water temperatures after flow adjustment. – Monitoring suspect set of bellows in the Storage Ring (150mA 900 bunches). July 2010 – Monitoring Booster RF Cavity water temperatures with increasing power. Aug 2010 – Monitoring suspect set of bellows in the Storage Ring (150mA & 200mA 600 bunches). Sept to Nov 2010 – Monitoring of new ‘Mini Beta’ components in Storage Ring (200mA, 900 & 600 bunches and hybrid fills) Apr 2011 - Monitoring of second installation of ‘Mini Beta’ components in Storage Ring. Adrian Johnson. ARW2011 10-15 April 2011

Booster RF Cavity Cooling – Results (appendix) RF Off RF On 50kW CW RF On normal ramp Adrian Johnson. ARW2011 10-15 April 2011

Remote desktop set up (appendix) Adrian Johnson. ARW2011 10-15 April 2011