1. PACMAN Workshop OUTLINE Introduction ESR 3.1 Challenges - Stability budget and Precision Mechanical Design - Precision Assembly of MBQ and BPM - System Integration Done and Undergoing Future CERN 03/02/2015 by Iordan Doytchinov “If you grasp the principles – myths fall & Ideas take-off” David Lentink (TUDELFT) TED Conference Amsterdam (“ برج خليفة ‎, "Khalifa Tower“) – Dubai 2010 Babylon tower by Tobias Verhaecht (1561 – 1631)

2. CLIC Challenge 2 200m 2m CLIC alignment Challenge: Calibrate and pre-align all critical components to allow maximum error of 17µm (diameter of a cylinder) over 200 meters length of sliding window of assembled components 17 µm Never done before. Needed for ~50km future colliders! 2 meter section of the Accelerator

3. Steps AS structures and BPM MBQ Zero of components to fiducials [µm] 510 Fiducials to sensor interface on support [µm] 55 Sensor interface to sensor zero [µm] 55 Sensor measurement w.r.t straight reference [µm] 55 Stability knowledge of the straight reference [µm] 10 1417 The PACMAN system targets 3 Girders Alignment Budget CLIC Physicists requirements for CLIC to operate Pre-alignment PACMAN Uncertainty budget [µm] @BPM 6.78 @MBQ 11.8

4. Mechanical Stability for PACMAN system y X Z Uncertainty Sphere with Diameter Uc(y) of 6.78µm for BPM and 11.8µm for MBQ y X Z Real time RF or Magnetic Centre Real time RF Centre Real time Magnetic centre Stretched wire Coordinate centre of Reference System by 3x ceramic balls

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6. Mechanical Stability for PACMAN system [1] Stability of Optical Elements in the NIF Target Area Building [David J. Trummer, Richard J. Foley, Gene S. Shaw]

7. Mechanical Stability for PACMAN system Uncertainty InputOnly Rotation (Θz+αx)OR Σ = sqrt(Rot^2 + Translation^2) U(structural) ?OR ? ? U(Thermal Transient) ?OR ? ? U(Contingency) ?OR ? ? TOTAL: U(Mechanical Errors Drift) 2.99µrad – 0.618 arcsOR 5-6µm m m m Translation or rotation on Y axis irrelevant for magnetic or RF field alignment α

8. Assembly of MBQ and BPM 8 8 Design Manufac turing Hard/expensive to optimise Measurement + evaluation Magnetic measurement Assembly stage + jig/tooling  The problem: Mechanical Uncertainties Correlated to Magnetic uncertainty  How the assembly cycle and correlated uncertainties can be deterministically controlled? - Integrate CAD,CAM, CMM, Magnetic measurement into one cycle? Use information real time at assembly?

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10. PACMAN ESR 3.1 Assembly of MBQ and BPM 10 BPM mechanical Centre Magnet mechanical centre Volumetric assembly tolerance zone cylinder  Match the real-time RF and Magnetic centres to required accuracy for error compensation [2] 0.3mm Distance from the centre [mm] [2] Design of the 15GHz BPM Test Bench for the CLIC Test Facility to perform precise stretched wire RF measurements: Silvia Zorzettiy, Luca Fanucciy, Natalia Galindo Mu~noz and Manfred Wendt Assembly accuracy desired = Linear_region_size - [(Magnetic measurement uncertainty) +(RF measurement uncertainty)] = 0.54mm  Vacuum enabling enabling interface to butterfly vessel!  Electrical connectors feed-trough  Confined space  High assembly repeatability,  Mechanical and thermal transient stability (critical assembly!)

11. PACMAN ESR 3.1 Sub-System Integration to Final system ESR 3.1 Other PhD Researchers Monitoring sub-systems specification and their development for any integration issues! Magnetic Measurement None-Contact CMM Head/Micro triangulation - Wire Localization BPM Measurement RF Cavity Measurement Need Requirements ‘Clients’ Integrated system requirements Need Requirements

12. Activities done so far and undergoing: 12  Technical trainings (metrology, tolerancing, CATIA, ANSYS, etc.)  System Integration studies  Magnet assembly studies (on existing MBQ prototypes)  Mechanical error budget studies  Initial Literature survey  Industrial survey and relations (GD&T analysis software's) 3dcs, sigmetrix, KOTEM  Link with QVI/KOTEM technologies and Metrosage on possible future collaboration  BPM/MBQ connector 1 st conceptual design  Planning for first Integration Thermal vs Vibrations VS Magnetic Issues experiment

13. Future plans 13  Complete literature survey for 1 year Review at Cranfield University  DMP secondment?  Thermal vs. Vibrations vs. Magnet centre shift issues experiments  BPM/MBQ precision connector design/manufacture + evaluation  Further magnet assembly test  Further uncertainty estimation investigation  Further system integration investigation More development in:  Investigation relationship between real component shape and corelated magnetic errors. (possible collaboration with KOTEM) - Further specific literature survey in the area - assembly method including GD&T software and real-time data - assembly jig design

14. Thank you for your attention, Any questions? 14 “Errors, like straws, upon the surface flow; He who would search for pearls, must dive below.” ― John Dryden, All for LoveJohn DrydenAll for Love

15. BPM Concept 15