1. DOE Review of the LCLS Project (SLAC) October 24-26, 2006 Single Undulator Test and Integration
Geoff Pile

2. Overview of results from the Single Undulator Tests
Information taken from various presentations of “An Internal SUT review”
Thanks to the SUT construction team.

3. Our First Renderings of the SUT

4. Original Goals of the Single Undulator Test
Provide critical input to the S/M system design reviews.
Help to determine whether the support/mover system design is ready for final production.
Measurement of girder and rollaway motions
Determine precision and reproducibility of motions, including start and stop. Check for interference
Measure vibration damping or (hopefully not) amplification.
Measure position stability and temperature dependence of components and subcomponents.
Practice Undulator replacement technique on SUT translation stages
Enhance the Final Integrated Design for production

5. The actual SUT set up in MM1

6. The Test Plan Included Support Mover System Testing
Control System Testing
Mock Vacuum System Testing
Diagnostic & Quad System Testing
Kinematic Undulator Replacement
Alignment Checks/Tests

7. Support/Mover System Testing

8. Support/Mover System Testing
Salient Support/Mover System Physics Requirements:
Quadrupole Motion Positioning Repeatability ±7 µm
Quad. Center Stability after Fiducialization ±10 µm
Short-Term (1 h) BPM and Quad Stability ±2 µm
Long-Term (24 h) BPM and Quad Stability ±5 µm
Horiz. Segment Pos. Repeatability in Roll-Away Cycle ±10 µm
Vert. Segment Pos. Repeatability in Roll-Away Cycle ±5 µm
Quad Transverse Position Change in Roll-Out Condition ±25 µm
Quad Position Reproducibility after Roll-Away Cycle ±2 µm
BPM Transverse Position Change in Roll-Out Condition ±25 µm
BPM Position Reproducibility after Roll-Away Cycle ±2 µm
* Note: The MM1 Facility Lacks Adequate Temperature Control

9. Support Mover System Testing
SUT Keyence CCD Laser Displacement Sensor Layout

10. Support/Mover System Testing
Sensor Name
Measuring Range
Resolution
Sensor Measurement Function
XUpstream
± 5 mm
0.05 µm
Horizontal Upstream Beam Center Position; BFW Manual Stage
YUpstream
Vertical Upstream Beam Center Position; BFW Manual Stage
XDownstream
Horizontal Downstream Beam Center Position; BPM Manual Stage
YDownstream
Vertical Downstream Beam Center Position; BPM Manual Stage
YMidstream
Middle Edge of Girder at Beam Height for System Roll
XQuad
Horizontal Position at Beam Height for Quad Manual Stage
YQuad
Vertical Position at Beam Height for Quad Manual Stage
XUpstream Translation
± 40 mm
0.5 µm
Upstream Undulator Segment Position for Roll-Away System
XDownstream Translation
Downstream Undulator Segment Position for Roll-Away System
YFloor 1
-250 mm/+500 mm
2.0 µm
Upstream Outboard Vertical Position of Girder Relative to Floor
YFloor 2
Downstream Outboard Vertical Position of Girder Relative to Floor
YFloor 3
Inboard Middle Edge Vertical Position of Girder Relative to Floor

11. Support/Mover System Testing
XDownstream Translation
YQuad
XQuad
XDownstream
YDownstream
YFloor 2

12. LCLS Undulator Roll out Requirements 8.12
Support/Mover Roll out System Testing
LCLS Undulator Roll out Requirements 8.12
Wire center  40 mm (not in PRD)
in ID roll-out condition.
Girder Upstream
BPM/Quad center  25 mm
in ID roll-out condition.
Girder Downstream
Total weight: ~4060 lbs. ID weight: 2140 lbs.
ID motion range: 80 mm.
Load change max: ~ +/-350 lbs.

13. Test Results with the Original System
Support/Mover Roll out System Testing
Test Results with the Original System
Wire center X=16 mm, Y=37 mm
in ID roll-out condition.
Girder Upstream
CAM 4
CAM 5
BPM/Quad center X=103 mm, Y=10 mm
in ID roll-out condition.
Girder Downstream
CAM 1
CAM 2
CAM 3

14. Fully optimized system meets spec
Modified Downstream Wedge Blocks both from 45 to 25.6 and 43°
Test Results with the Cam System swapped end to end with 1 modified wedge block (overcorrected negative)
Wire center X=66 mm, Y=22 mm
in ID roll-out condition.
CAM 2
Girder Upstream
CAM 3
CAM 1
BPM/Quad center X=-23 mm, Y=-12 mm
in ID roll-out condition.
Girder Downstream
CAM 5
CAM 4
Fully optimized system meets spec

15. Modified Downstream Outboard Wedge Block from 45 to 25.6/41.9°
Readings from the Keyence Sensors During a Full Cycle of the 80 mm. Roll-Out and Roll-In Cycles (2 sets of data/round trip)

16. Support/Mover System Testing
Conclusions:
The Cam-Mover System Tests Resolution and Backlash Results are Excellent for all Degrees of Motion Freedom and Well Within Specifications
With Feedback Added, The Cam-Mover System is Able to Achieve Any Move Within the Command Space to Within 2 µm with No More Than One Iteration
The Roll-Away System Backlash and Resolution Results are Excellent and Well Within Specifications
All Motions for Both Motion Systems are Extremely Repeatable
With the New Gearbox Design Motor Heating Effects are Non-Existent
Engineering Solutions to Make the System Even Better are Underway

17. Control System Testing

18. Control System Testing
The electronic rack for the SUT incorporates most of the hardware control systems for the undulator components.
It requires 120 volts and an Ethernet connection.
The real rack will conform to SLAC rack systems & earthquake specs

19. Control System Testing
The SUT control system is based on Lab View.
Here is the main operating screen
The Epics control system will be utilized on the Long Term Tests
The engineering & operating screens will be designed and integrated with SLAC (Stein, Xu and Dalesio)

20. Control System Testing
Wiring on SUT was point to point traditionally wired. Prototype cableway for control and monitoring system has been developed. Locates under Undulator Girder. Final design is being reviewed now.
Vendor-made with standardized connectors. >30 matching cables will be manufactured to interconnect with hardware e.g. motors, thermocouples, potentiometers, BFW, etc. etc.
33 cableways needed x 30 cables each = ~1000 cables. Installation will be easy – commissioning will be even easier due to ISO 9000 build and testing.

21. Control System Testing
Special test equipment was constructed to aid with control system testing.
Keyence
Inclinometer
Thermal
Vibration

22. Mock Vacuum System Testing

23. Vacuum Chamber Adjustment Mechanism
Compound screws - 5/8-18 screw /16-20 screw
Z-adjustment 5/16-18 screws
X-adjustment 5/16-18 screw
Y Vertical Adjustment - Compound screws
Total 26 threaded holes
14 screws for vertical adjustment
Other 12 threaded holes for lifting / adjustments
X-Z Horizontal Adjustments – Cap screws

24. Compound Screw Tests
Performed the compound screw adjustment tests (2, 6, 14 screws).
Adjustment test showed that it is possible to get fine adjustment, but it was cumbersome to align. It also showed that the locking nut makes the process difficult, but that it is sufficient to use. It works in both directions to adjust the vertical height of the mockup.
A laboratory test is set-up with a single compound screw and with the proper selection of materials, EP SST and MoS2 lub, also brass. The backlash is small enough not to hinder micron level adjustments.
Finally, we chose 5/8-18 Brass and 7/16-20 SST compound screws to prevent galling
Six Compound Screws Set-up (42” long)
Fourteen Compound Screws Full Chamber Mock-up

25. Lifting tests
Lifting spreader was designed to help lifting up the vacuum chamber assembly and lifting plan was documented.
Lifting spreader was certified from the ES&H inspector after QA inspection and static load test (500 lb).
No hazards found during the chamber installation.
Figure Figure Figure 9.

26. Breakdown of the spacing between the undulator and the vacuum chamber

27. Mock Vacuum System Testing Vacuum Chamber alignment
[mm]
Vertical Adjustment Screws (14)

28. Diagnostic Systems Testing
Ersatz Quad, Beam Position Monitor and Beam Finder Wire alignment and positioning was successful.
The Support and translation systems for these items have been studied and the designs are acceptable. All positioning and roll out specs have been met.

29. Assemblies and Cross Sections
Assembly
Bellows Flange
BFW Flange Seal
Locating Pins
Beam Tube Spider
Shielding Cut-out
Vacuum
Flange
Vacuum
Chamber
Flange

30. Diagnostic Systems Testing
Beam Finder Wire
As part of the SUT, vibration tests were run on a BFW system mock-up. The mock-up was sufficiently stable.
As part of the SUT, the mounting system for the BFW was tested for positioning accuracy. The mount system can locate the Chamber to within +/- 10 µm in X and Y.

31. Kinematic Undulator Replacement

32. SUT Undulator Segment Replacement Testing
Background:
The Magnetic Axis of each Undulator Segment is Fiducialized to a Fixed Horizontal and Vertical Dimension using Shim Plates Underneath and on the Ends of the Undulator Support Plates in order to make all Undulator Segments Identical and Interchangeable.
When Referenced to the Undulator Alignment Pins on the Stage Transition Plates, Undulator Segments can be Interchanged Without the need for Realignment.
The Total Tolerance Budget Mandates that this Process Must be Repeatable to within 180 µm rms Horizontally and 70 µm rms Vertically*. In Reality, the Process Needs to be Repeatable to Within a Percentage of this Tolerance to Allow for Additional Tolerance Stack Up Elsewhere.
Purpose:
Using only One Undulator Segment, Determine the Positioning Repeatability at Both End of the Undulator after Removal and Reinstallation.
* From Robert Ruland’s 7/7/05 Presentation “Alignment Considerations”

33. SUT Undulator Segment Replacement Testing
Threaded Stud Guides
Undulator Support Plate
Stage Transition Plate
Undulator Alignment Pins
Horizontal Thick Shim

34. Lifting/Positioning Fixture
SUT Undulator Segment Replacement Testing
Lifting/Positioning Fixture

35. SUT Undulator Segment Replacement Testing
August 2006 Testing Method:
Dual Sets of Four Keyence Sensors were used to Measure the X and Y Displacement at Both Ends of the Undulators Relative to the Girder. The “Dummy” Undulator and the Actual Undulator had their Own Dedicated Set of Keyence Sensors so that “Zero” Positions Could be Maintained when Switching Between the 2 Undulators
Positions were Zeroed at the Undulator “Zero” Position. The Undulator was then Retracted to the 80 mm Position, Unbolted and Removed from the Stages using our Lifting and Positioning Fixtures.
The Weight of the Undulator was Removed from the Girder using a Forklift.
The Undulator was then Lowered to the Lifting Fixtures and Brought back Down onto the Stages.
Bolts were Retightened using a Torque Wrench and then the Undulator was Returned to the Home “Zero” Position. The Keyence Sensors were Read and Recorded at this Time and Compared with the Laser Tracker System Results.
This Method was Repeated 4 Times for the “Dummy” Undulator and 3 Times for the Actual Undulator.

36. SUT Undulator Segment Replacement Testing
Xupstream
Yupstream

37. SUT Undulator Segment Replacement Testing

38. Kinematic replacement of undulator Conclusions:
SUT Undulator Segment Replacement Testing
Kinematic replacement of undulator Conclusions:
The Process of Replacing an Undulator Segment is Quick and Easy Using the Lifting and Positioning Fixtures.
The Process is Very Accurate and Repeatable.
The Worst Case Repeatability for Vertical Alignment is Less than 10 Microns.
The Worst Case Repeatability for Horizontal Alignment is Less than 40 Microns.
The Laser Tracker Network Established around the SUT Provides Excellent Results that are in Good Agreement with the Keyence Sensor Measurements.
The Laser Tracker Network will be Used Throughout SUT Testing to Provide a Secondary Set of Measurements for Comparison to The Keyence Sensors and Positioning Potentiometers.

39. Support/Mover System Testing
Survey & Alignment Support:
LEICA LTD 500 Laser Tracker System Used for System Alignment
Local Reference Network Established with 9 Fixed Monuments Distributed Around the SUT at Various Elevations
Largest Measured Distance was around 3.5 m and Thus the Measurement Accuracy was On the Order of Tens of Microns
Mini-Monuments Used on the Girder, Undulator, and Fixed Bases for Alignment of these Components. Tracker Also Used to Set Translation Stage Alignment Pins
Optical Level System Used to Align Vacuum Chamber
Taylor-Hobson Talyvel 4 Used for System Distortion Measurements During the Roll-Away Cycle

40. Final Alignment Summary
Support/Mover System Testing
Final Alignment Summary
Support Stands were set in elevation, pitch and roll to mm.
The Interface Plates fell within 0.05 mm in all areas.
Final alignment of the girder was achieved to within ±10 µm in pitch, roll and elevation, yaw and x were within ±40 µm.
80mm roll out tests were successfully tracked with the laser and compared very well against Keyence sensor results.

41. So how did we do? - We learned a lot!
Support Mover (inc. fixed supports) System Testing
Initial tests were very successful – Most of the requirements have been achieved and we learned what we had to change to meet or exceed the remaining requirements. Final designs will incorporate all of the experience we gained and changes required to meet these specs.
Changes include modifications to the fixed supports, girder, translation stages, wedge blocks, cam movers and gearboxes.
Undulator Roll Out
Testing and rapid wedge block development has resolved very challenging specs that could have been a significant problem.
Kinematic Undulator Replacement
Initial tests (dummy only) were very successful – We appeared to be well in spec but had to complete the tests with the First Article # 1 and the dummy undulator. Final numbers are well in spec. Making all undulator equal in production will be a relatively easy process.
Diagnostic System Testing
Initial installation, alignment and integration of ersatz BPM and BFW look very good.
Setting the stages (settability) to a “go to” position is very good.

42. Final Design enhancements
Larger clearance holes on the base plate.
More anchor points around the base plate.
Illustration of possible mounting points. (8) total points will be used in the final design.
Larger diameter support structure.
Standard parts will be investigated for this improvement.
Larger threaded rods between the base top plate and the interface plate.
Thinner grout with an improved floor mounting method.

43. Design Summary Earthquake Restraints Cam Mounting Pads
1 ½” Interface Plate
1 ½” Top Plate
1½” Support Rod
3” Fiber Wool Insulation
(Not Shown)
1”- 8 Base Leveling / Anchor Bolts
Silica Sand
Stand Cap
1 ½” Bottom Plate
Support Pads
Expanding Grout
(Not Shown)

44. Integration

45. Integration
Rodd Pope is talking about schedule and assembly integration at SLAC. Here’s a different look at an example of some of our project integration.
in‧te‧grate  ˈɪn tɪˌgreɪt
–verb (used with object) 1
to make up, combine, or complete to produce a whole or a larger unit, as parts do. 2
to bring together or incorporate (parts) into a whole.
We made up the following integration tool and are currently developing it. It will be web accessible by Lehman Review.

46. Integration
We all need to ASK for information to integrate efficiently.
This is called the ASK system.
Assembly
Sub-assembly
Kit
Example:
Select Support mover on this interactive web page.
Support Mover box opens up main three areas
2. Select Fixed Support

47. Integration Fixed Support Assembly. wbs 1.04.03.08 B.O.M A.S.K. S.O.W
Installation info

48. Integration

49. Integration Microsoft Access Links – P3 Information
PARIS Procurement info
Intralink
Free form entry allows input from QAR CAMs & SLAC integration engineers.