1. Undulator Assembly Procedure
LCLS Review
11/15/04
Mark Erdmann

2. Mark Erdmann / LCLS Review
Assembly Plan
LCLS will provide strongbacks, poles, and sorted magnets to assembly vendor
Assembly vendor will fabricate remaining parts
Assembly will be according to LCLS procedure
12/2/2018
Mark Erdmann / LCLS Review

3. Mark Erdmann / LCLS Review
Assembly Procedure
Closely follows experience of prototype assembly
Improved and simplified by value added engineering changes
Poles with a more basic design but tighter tolerances
Pole sorting not required
One piece base plate versus 3 pieces
Assembly can easily be performed by mechanical shop without previous undulator or permanent magnet experience
12/2/2018
Mark Erdmann / LCLS Review

4. Mark Erdmann / LCLS Review
Step 1: Check 10% of incoming poles to verify they meet the height specification.
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Mark Erdmann / LCLS Review

5. Mark Erdmann / LCLS Review
Step 2: Attach 1st pole assembly fixture to the magnet / pole base plate.
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Mark Erdmann / LCLS Review

6. Mark Erdmann / LCLS Review
Step 3: Install poles onto the base plate, starting on the upstream side.
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Mark Erdmann / LCLS Review

7. Mark Erdmann / LCLS Review
Step 4: Attach 2nd pole assembly fixture and continue installing poles until entire magnetic structure is full.
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Mark Erdmann / LCLS Review

8. Mark Erdmann / LCLS Review
Step 5: Obtain magnetic field data from manufacturer and sort magnets. Manually install magnets and clamps.
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Mark Erdmann / LCLS Review

9. Mark Erdmann / LCLS Review
Step 6: Assemble the top and bottom magnetic structures using the assembly fixture.
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Mark Erdmann / LCLS Review

10. Mark Erdmann / LCLS Review
Conclusions
This assembly procedure has been proven to work on the prototype LCLS undulator.
Manual insertion of permanent magnets is a safe and reliable method of assembly.
Method can easily be transferred to industry for large quantity assemblies.
12/2/2018
Mark Erdmann / LCLS Review