CLIC Permanent Magnet Quadrupole update 1 st December 2010 Mechanical Engineering status N. Collomb1

Presentation Topics Integration issues from previous iteration Design revision and envelope check Development comparison and dimensional changes Assembly Sequence considerations Future plans Corrector Feature N. Collomb2

Integration issues N. Collomb3 Motor posed an issue

Integration issues N. Collomb4 Mechanism clash with Flange and Vessel Interference clash with girder Gearbox bracket interfering with vacuum pump

Integration issues CAD-QA showed clashes in integration model –Motor and Flange –Mechanism and vacuum vessel –Gearbox bracket and vacuum pump –Mechanism brackets on ‘front’ and girder –Height and girder interface Magnet aperture was larger than specified BPM coupled to magnet Shimmed vacuum vessel prevented correction in vertical and horizontal plane. N. Collomb5

Revision of mechanical design Reduction in width to prevent clashes Remodelling with respect to magnetic design update Correction of aperture Review of components due to forces change and clashes Assembly process instigation and design implications Interface with girder consideration Correction features N. Collomb6

Envelope check N. Collomb7 Placed box on girder. Box: 391x391x270mm No interference Interference No interference, just

Current Development N. Collomb8 Major changes: 1.Motor moved to top (vertical) 2.T-Gearbox different 3.Side-plate with rails continuous 4.Core – faceplate redesigned 5.Yoke Assembly redesigned 6.Cap – faceplate size reduction 7.Ball-screw nut bracket shallower and 1 piece Previous schematic

Dimensions (figures in brackets from previous schematic) N. Collomb mm (438.5) mm (368.5) 850 mm (654) 388 mm (385) 270 mm (262) 230 mm magnet Aperture Ø70 mm 260 mm Nosepole aperture: Ø28 mm

Assembly Sequence Initial strength calculations indicate feasibility of design is OK. Discussion with manufacturers about sub- assemblies in progress – influences assembly sequence. Design broken down into 5 key stages –Magnet core –Core –Linear motion system –Motor and Gearbox –Final Assembly N. Collomb10

Assembly Sequence – Magnet Core N. Collomb11 Supplier provides assembly: Permanent Magnet Magnetic steel plateAlu Strap: tensions Strap and supports PM Strap plate to prevent mechanical failure Magnetic steel centre

Assembly Sequence - Core N. Collomb12 Magnet Core (ref)Magnetic steel Yoke Alu Core support (doweled) Face - plates Core can be split into ‘Top’ and ‘Bottom’ halves. Face – plates maintain horizontal positioning, Core supports maintain vertical positioning to ensure inscribed nose-pole radius is accurate. Magnet Cores (top removed for clarity) serve as reference.

Assembly Sequence – Linear Motion System N. Collomb13 Ball-screw nut bracket Adjustable Ball-screw Support bearings Side Mounting Plate Ball-screw nut Linear Motion Rails Linear Motion Runners 22 mm Could reduce magnet overall- width by 20x2 mm at cost of backlash couplings.

Assembly Sequence – Motor & Gearbox N. Collomb14 T- Gearbox ratio 2:1 Brackets can be combined into one piece, still permitting alignment. 400 step/rev Stepper motor, 1.8° accuracy Right Angle Gearbox ratio 25:1 Backlash coupling

Assembly Sequence – Top Level N. Collomb15 Core Magnet Assembly and Core brought together in controlled manner in jig. Dowelled and secured. Step1 is to fasten Side- plate Assembly to Centre Assembly. Secured only. Step 2 is to fasten Face- plates. Align and adjust as required. (D.o.F.) Dowelled and secured.

Assembly Sequence – Top Level N. Collomb16 Backlash Coupling and Gearbox bracket pre- assembly. Secured only Motor and Gearbox assembly lowered onto ball screw ends align and secure before pre-tensioning. Dowelling. Motor conditioning. Single gearbox assembly bracket in progress.

Assembly effects for manufacturing Outsourcing certain sub-assembly advantages are the expertise and infrastructure manufacturers possess. Collaboration with manufacturers has started (hypothetical mass production discussions). Some components can be eliminated by incorporating their function into one part. Splitting the magnet is still possible to insert the vacuum chamber during installation – however I propose to include the vacuum chamber during initial assembly. N. Collomb17

Revision of future plans Revise time of deliverables –FEA and optimisation (partially complete) – Jan11 –Design evaluation (in progress) - Dec 10 –Assembly plan (in progress) – Dec 10 –Integration (model send to Dimitry) – Nov 10 –Design and development of corrector – Jan 11 –Costing and procurement – Feb 11 –Prototyping – June/July 11 –Assembly/Testing – July/Aug 11 N. Collomb18

Corrector feature Integration illustrations indicate that this feature must be located on the side on the girder magnet interface. It MUST NOT add height other than what is required Aperture permits a ±1.4 mm vertical or horizontal movement (Magnet aperture Ø28 mm and Vacuum vessel O.D. 26 mm) Requirement for movement ±0.5 mm means we can reduce the magnet aperture to Ø27 mm (±0.7mm achievable). N. Collomb19

Corrector feature Interface between magnet and girder not designed yet. Design to commence once integration has cleared magnet envelope. Questions: –Can the girder be modified in terms of additional holes for instance? –Do other components occupy space below reference surface adjacent to magnet? –Is the girder hollow and if so can we mount items from underneath? –Can you supply a model of the girder (blank)? N. Collomb20

Summary We are closing in on a feasible design. Provided the integration shows the magnet can fit in the space allocated on the module, then a prototype can be started to be procured in February Manufacturers are keen and provide advice and guidance in terms of cost – functionality. Accuracy, repeatability and precision can be achieved to meet specification. Time plan has slipped slightly with prototypes still available for third quarter James Richmond continues on project as part of his University degree. N. Collomb21

Questions? N. Collomb22