Conventional Insertion Devices WBS U John Grimmer Technical Lead, Conventional IDs System Manager, Insertion Devices Accelerator Systems Division/Magnetic Devices Group DOE Lehman CD-2 Review of APS-Upgrade 4-6 December 2012

Outline  WBS Scope Insertion Devices (excluding , Superconducting Undulators)  Staff / Org Chart  Requirements  Scope Details  Design  Value Engineering  Prior Review Recommendations  ES&H  Cost  Schedule  Summary 2 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

Conventional Undulators Project Scope and WBS Level 4 U , U , U , U , & U A dual, canted undulator installation: two planar undulators, one canting magnet and one ID vacuum chamber in the APS storage ring. DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

4 Insertion Devices, Org Chart

Insertion Devices, Requirements  The insertion device requirements for APS-U are identified in Physics Requirements Documents (PRDs) and Interface Control Documents (ICDs).  Existing-period undulator designs will be used for the magnetic structures on most of the planar undulators, including the revolver undulators. One new design for a period shorter than existing designs is included in the APS-U scope and will support the medium-energy brightness KPP.  Revolver undulators must perform as “two undulators in the space of one” and meet the same field quality and beam perturbation specifications as the regular, planar undulators. They require special mechanical, electromechanical, and controls development, as well as design of revolver-compatible support stands for ID vacuum chambers. 5 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

Insertion Devices, Requirements  The EMVPU is required to provide linear vertical, linear horizontal, variable elliptical and circular polarization, as well as the ability to switch between left- and right-handed circular (or elliptical) polarization at 10 Hz.  Both APPLE-II undulators require magnetic field end corrections to minimize perturbation of the stored electron beam. The users of one APPLE-II undulator have requested a method for suppression of higher order harmonics in linear modes.  The insertion device activities support the APS-U KPP of 12 insertion devices installed. 6 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 * Breakdown of the 48 undulators currently installed at the APS.

Insertion Devices, Scope Details APS-U Planar Undulators (3)  Three planar, hybrid PM undulators will be built.  The required gap separation mechanisms and control systems are all proven designs, so no further development is scoped.  Most APS-U device magnetic structures (including revolver undulators) will be of existing APS period designs, but design of one new period, shorter than existing periods, is included as part of the APS-U scope. 7 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 Analysis of differential deflection of pole mounting shoulders under magnetic force.

Insertion Devices, Scope Details APS-U Polarizing Undulators (3) APS-U EMVPU (1) APS-U APPLE-II (2)  One electromagnetic, variable polarizing undulator (EMVPU) and a custom power supply will be built. Prototype development of the device itself and the required power supply are funded outside of APS-U through an FY ‘13 LDRD.  A special vacuum chamber to allow fast switching of the EMVPU will be designed as a part of APS-U. 8 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 CAD model of 4 period EMVPU prototype.

Insertion Devices, Scope Details APS-U Polarizing Undulators (3) APS-U EMVPU (1) APS-U APPLE-II (2)  Two APPLE-II devices will be purchased from an outside vendor, complete with basic control systems.  End correction schemes, magnets, and power supplies are included as a part of APS-U.  High-level controls and required interfaces will be designed as part of APS-U. 9 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 Schematic illustration, APPLE undulator design and operation. End view of APPLE undulator at SRC.

Insertion Devices, Scope Details APS-U Revolver Undulators (5)  Five revolver undulators and their control systems will be built.  Each revolver undulator will have two magnetic structure pairs like those of the planar undulators.  APS-U will adopt the successful designs of an ongoing LDRD- funded development program for revolver undulators and controls. 10 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 CAD model of one of the APS revolver undulator prototypes.

Insertion Devices, Scope Details APS-U Canting Magnets (8); Corrector Magnets (2)  Eight canting magnets, which include a dipole and a corrector, will be built, together with the required power supplies, for use in the APS-U dual, canted undulator sectors.  Two corrector magnets and their power supplies will be built for use upstream of the SPX cavities. 11 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 Canting dipole/corrector magnet installed in an APS dual, canted undulator sector. Canting Magnet Upstream Undulator Vacuum Chamber

Insertion Devices, Scope Details APS-U Insertion Device Vacuum Chambers (12) APS-U Standard, Canted & Long Straight Section (11) APS-U EMVPU (1)  Eleven ID vacuum chambers of extruded aluminum construction, with stainless steel endboxes, will be built. Design of a chamber allowing a slightly smaller ID gap is scoped, as is design of an APPLE-II-compatible chamber.  Revolver-compatible stands will be designed and built for each of these chambers. 12 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 CAD model of ID vacuum chamber extrusion, machined for dual, canted undulators. This part is then welded to two SS endboxes, which each have a bimetallic side. CAD model of ID vacuum chamber support stand

Insertion Devices, Scope Details APS-U Insertion Device Vacuum Chambers (12) APS-U Standard, Canted & Long Straight Section (11) APS-U EMVPU (1)  One ID vacuum chamber, likely of welded stainless steel construction with an internal copper coating, will be designed and built for the EMVPU. 13 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

Insertion Devices, Design - Planar Undulators  The APS has designed, built, and installed 15 undulators with periods of 2.3, 2.7, 3.0, 3.5 and 3.6 cms. APS-designed gap separation mechanisms are used for these and 15 others.  The magnetic structures of these devices are compatible with all of the planar undulators in APS-U, including the standard planar and the revolvers, in either full or canted length. 14 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 Full-length 2.7-cm-period undulator installed in upstream location in Sector 3 of the APS storage ring. Two full-length 3.0-cm-period undulators installed in Sector 30 of the APS storage ring.

Insertion Devices, Design - EMVPU  The development of the EMVPU exploits the magnetic and mechanical modeling, analysis, design, and measurement capabilities very successfully demonstrated by the APS in the recently-completed 4.8-m-long IEX electromagnetic undulator, shown below. 15 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December D CAD model of 4-period IEX prototype and actual prototype. 3-D CAD model of final IEX undulator and actual final undulator, ready for measurement.

Insertion Devices, Design - Revolver Undulators  Revolver undulators are mature technologies at other light sources. ESRF has had revolvers in operation for over a decade.  Revolver undulators were not envisioned when the design direction was set for IDs and ID vacuum chambers at the APS, so incorporating revolvers presents some challenges unique to the APS. (ID vacuum chamber/support design, need for gap tapering, 4-motor gap separation mechanism)  These issues are being addressed with an APS-specific revolver undulator development program, funded through an ANL LDRD. 16 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 Upper jaw of revolver undulator at ESRF. The ID vacuum chamber was designed to accept revolver undulators. End view of an early APS revolver undulator design and the existing ID vacuum chamber and support. The support must be redesigned to accommodate the unused lower magnetic structure in the outboard position.

Insertion Devices, Design - Revolver Undulators  Two main design concepts have been pursued. Both are based on the existing APS 4-motor gap separation mechanism.  Since the CD-1 review, single-jaw prototypes of each concept were designed, analyzed, fabricated and assembled. They are now being tested.  The single-jaw prototypes use an upper revolver jaw with two 3.3-cm period magnet structures and a non-revolving lower jaw with a single, 3.3-cm structure. 17 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 One revolver design approach uses a non-revolving strongback and only revolves the magnet structures and their mounts. Non-revolving strongback Revolver drive Magnet structures

Insertion Devices, Design - Revolver Undulators  Mechanical and electromechanical testing of the single-jaw prototypes with and without magnet structures, including magnetic measurement and tuning, will determine which design will be the basis for the final prototype.  The final prototype will have 2.7- and 3.0-cm period magnetic structures and both jaws will revolve.  The final prototype will be further measured and tested, including installation in the APS storage ring, before the design is used by APS-U. 18 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 Another revolver design approach uses a revolving strongback. Revolving strongback Wormgear axis (motor/gearhead is on back side) Magnet structures

Insertion Devices Value Engineering  Today’s APS designs for the undulator gap separation mechanisms and magnetic structures were value engineered from the original designs. They meet specifications that are more relevant, and in some cases less stringent, than those applied to earlier versions.  Today’s gap separation mechanism structure is welded steel vs. bolted aluminum in the earlier undulators. The maximum magnetic attractive force requirement was also reduced, saving structure and drive size and cost. The device changes gap faster, holds position more accurately, and is less susceptible to “cant” change over the gap range. 19 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 * A hybrid, permanent magnet undulator with APS-designed magnetic structures and gap separation mechanism being readied for magnetic measurement.

Insertion Devices Value Engineering  The magnetic structures have been simplified vs. earlier ones, but are more accurate as well, allowing easier magnetic tuning. They are also modular, so they can be converted between full and “canted” length (and back again, if desired).  The undulator control system was completely redesigned recently. It uses more off-the-shelf hardware to reduce both initial cost and maintenance cost. The control system also features greater gap feedback redundancy. 20 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 CAD model of APS-designed magnetic structure showing method of pole location and pole and magnet retention.

Insertion Devices, Prior Review Recommendations From CD-1: “The difficulty of the CPU and the increased changing polarization frequency needed of the EMVPU lead the committee to conclude that it is likely underestimated as to complexity, difficulty and risk.”  An LDRD is being pursued for prototype development of the device and power supply off-project. From CD-1: “The IDs group has engaged an external engineering firm for the design of the revolver mechanism. The qualifications of this external engineering firm in the specialized area of precision mechanisms was not cleanly identified and so the committee believes that comprehensive technical reviews by relevance subject matter experts will be necessary.”  A preliminary design review was held in July 2011, and a final design review of the single-jaw prototype was held in December From CD-1: “As ID installation occurs during the same scheduled shutdowns as regular deployed ID maintenance the same resources are double booked this resource conflict is not easily resolved and will need to be addressed prior to CD-2.”  This is being addressed through schedule sequencing in P6, through efforts at capturing all of the operations workload with the same rigor at the APS-U workload, and through efforts to scale and backfill the capabilities of key resources. 21 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

Insertion Devices ES&H DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December  Integrated Safety Management System (ISMS) –APS-U Project following Argonne’s ISMS program requirements –Argonne Integrated Safety Management System (ISMS) Description recently revised and submitted to DOE ASO Describes framework for integrating ESH requirements with mission objectives References Argonne LMS procedures which implement specific portions of the ISMS  Identify General Safeguards and Security Requirements –APS-U Project required to follow Argonne’s Operations Security Program (OPSEC) Master Plan  Identify General Safety Requirements to Specific WBS Level –Undulator permanent magnets require special handling and posting of high magnetic field warning signs. –The EMVPU requires electrical safety postings and procedures. –The revolver undulators will need additional guards, safety postings, and procedures due to the additional magnetic structures and mechanisms.

Conventional Undulators Project Scope and WBS Level 6 U , U , U , U , & U DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

Conventional Undulators Project Scope and WBS Level 6 U , U , U , U , & U DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

Cost Estimation Drilldown Example U , Revolver Undulator Magnetic Structures (Cost Support for Award) DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December Cost without 1.5% for shipping Adding 1.5% gives the $435k total in P6. For the 5 structures, total cost is 5 x $435k = $2,175k

Conventional Undulators Project Obligation Profile U , U , U , U , & U DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 EMVPU Installation APPLE II Tuning & Installation; Assembly of EMVPU APPLE II Procurements & Controls/Corrector Design; EMVPU Final Design; First Revolver Installed First Installations; First Revolver Procurements RIXS, ASL & ID Vacuum Chamber Design & Procurement

Conventional Undulators Summary Schedule U , U , U , U , & U DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December /14 RIXS Undulator & ID Vacuum Chamber Installation 9/15 First Revolver Undulator Installation 1/16-5/17 Polarizing Undulator Installations

Conventional Undulators BOE Contingency U , U , U , U , & U DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

Near-term Insertion Devices Activities for CD-3a  Design a new period undulator for RIXS, likely 1.75-cm-period, depending on allowable minimum gap, as defined by ongoing ID vacuum chamber development.  Begin procurement of magnets, poles, magnetic structures, gap separation mechanisms and control systems for two of these undulators.  Define the period for the ASL undulator and begin procurement of magnets, poles, and magnetic structures for that undulator. (The gap separation mechanism is not included in the early activities.) 29 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

Key Insertion Devices Work Between CD-2 and CD-3 APS Upgrade:  Design a new ID vacuum chamber and revolver undulator- compatible stands; review design; begin procurement of chamber extrusions.  Complete and review designs for planar undulators, revolver undulators, and canting magnets. Expected deliverables to APS Upgrade:  Finish testing of the revolver undulators and complete design of the final revolver prototype.  Design and build a short prototype of the EMVPU – externally funded.  Further investigate tuning methods applicable to APPLE-II undulators; qualify vendors for APPLE-II procurements. 30 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

Insertion Devices Summary 31  The insertion device scope is clearly defined to meet the beamline requirements of the APS upgrade.  The preliminary design for conventional insertion devices is complete.  The cost is $17,828k dollars.  We are ready for CD-2! DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012