1. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Single Undulator Test and Integration Geoff Pile

2. Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS 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. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Our First Renderings of the SUT

4. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS 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. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS The actual SUT set up in MM1

6. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS 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. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Support/Mover System Testing

8. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS 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. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Support Mover System Testing SUT Keyence CCD Laser Displacement Sensor Layout

10. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Support/Mover System Testing Sensor NameMeasuring RangeResolutionSensor Measurement Function X Upstream ± 5 mm0.05 µmHorizontal Upstream Beam Center Position; BFW Manual Stage Y Upstream ± 5 mm0.05 µmVertical Upstream Beam Center Position; BFW Manual Stage X Downstream ± 5 mm0.05 µmHorizontal Downstream Beam Center Position; BPM Manual Stage Y Downstream ± 5 mm0.05 µmVertical Downstream Beam Center Position; BPM Manual Stage Y Midstream ± 5 mm0.05 µmMiddle Edge of Girder at Beam Height for System Roll X Quad ± 5 mm0.05 µmHorizontal Position at Beam Height for Quad Manual Stage Y Quad ± 5 mm0.05 µmVertical Position at Beam Height for Quad Manual Stage X Upstream Translation ± 40 mm0.5 µmUpstream Undulator Segment Position for Roll-Away System X Downstream Translation ± 40 mm0.5 µmDownstream Undulator Segment Position for Roll-Away System Y Floor 1 -250 mm/+500 mm2.0 µmUpstream Outboard Vertical Position of Girder Relative to Floor Y Floor 2 -250 mm/+500 mm2.0 µmDownstream Outboard Vertical Position of Girder Relative to Floor Y Floor 3 -250 mm/+500 mm2.0 µmInboard Middle Edge Vertical Position of Girder Relative to Floor

11. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Support/Mover System Testing X Downstream Translation X Quad Y Quad Y Floor 2 X Downstream Y Downstream

12. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS LCLS Undulator Roll out Requirements 8.12 Girder Upstream Girder Downstream BPM/Quad center   25  m in ID roll-out condition. Wire center   40  m (not in PRD) in ID roll-out condition. Total weight: ~4060 lbs. ID weight: 2140 lbs. ID motion range: 80 mm. Load change max: ~ +/-350 lbs. Support/Mover Roll out System Testing

13. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Test Results with the Original System Girder Upstream CAM 5 CAM 2 CAM 4 Girder Downstream CAM 3CAM 1 BPM/Quad center X=103  m, Y=10  m in ID roll-out condition. Wire center X=16  m, Y=37  m in ID roll-out condition. Support/Mover Roll out System Testing

14. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Test Results with the Cam System swapped end to end with 1 modified wedge block (overcorrected negative) CAM 2 Girder Upstream CAM 3CAM 1 BPM/Quad center X=-23  m, Y=-12  m in ID roll-out condition. Wire center X=66  m, Y=22  m in ID roll-out condition. Girder Downstream CAM 5CAM 4 Fully optimized system meets spec Modified Downstream Wedge Blocks both from 45 to 25.6 and 43°

15. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS 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) Modified Downstream Outboard Wedge Block from 45 to 25.6/41.9°

16. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS 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. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Control System Testing

18. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS 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. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS 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. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS 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. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Control System Testing Special test equipment was constructed to aid with control system testing. Keyence Inclinometer Thermal Vibration

22. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Mock Vacuum System Testing

23. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Vacuum Chamber Adjustment Mechanism Compound screws - 5/8-18 screw - 7/16-20 screw X-adjustment 5/16-18 screw Z-adjustment 5/16-18 screws 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. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS 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 Fourteen Compound Screws Full Chamber Mock-up Six Compound Screws Set-up (42” long)

25. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS 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 7. Figure 8. Figure 9.

26. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Breakdown of the spacing between the undulator and the vacuum chamber

27. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Mock Vacuum System Testing Vacuum Chamber alignment Vertical Adjustment Screws (14) [  m]

28. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS 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. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Assemblies and Cross Sections Assembly Vacuum Chamber Flange Locating Pins Bellows Flange Shielding Cut-out BFW Flange Seal Vacuum Flange Beam Tube Spider

30. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS 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. Diagnostic Systems Testing

31. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Kinematic Undulator Replacement

32. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS 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. * From Robert Ruland’s 7/7/05 Presentation “Alignment Considerations” Purpose: Using only One Undulator Segment, Determine the Positioning Repeatability at Both End of the Undulator after Removal and Reinstallation.

33. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS SUT Undulator Segment Replacement Testing Threaded Stud Guides Undulator Support Plate Stage Transition Plate Undulator Alignment Pins Horizontal Thick Shim

34. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS SUT Undulator Segment Replacement Testing Lifting/Positioning Fixture

35. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS 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. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS SUT Undulator Segment Replacement Testing X upstream Y upstream

37. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS SUT Undulator Segment Replacement Testing

38. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS 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. SUT Undulator Segment Replacement Testing

39. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS 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. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Final Alignment Summary Support Stands were set in elevation, pitch and roll to + 0.10 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. Support/Mover System Testing

41. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS 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. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS 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. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Design Summary 1 ½” Interface Plate 1 ½” Top Plate 1½” Support Rod 1 ½” Bottom Plate 1”- 8 Base Leveling / Anchor Bolts Expanding Grout (Not Shown) 3” Fiber Wool Insulation (Not Shown) Silica Sand Stand Cap Cam Mounting Pads Support Pads Earthquake Restraints

44. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Integration

45. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS 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 ˈɪ n t ɪˌ gre ɪ t –verb (used with object) 2to bring together or incorporate (parts) into a whole. 1 to make up, combine, or complete to produce a whole or a larger unit, as parts do. We made up the following integration tool and are currently developing it. It will be web accessible by Lehman Review.

46. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Integration Example: 1.Select Support mover on this interactive web page. Support Mover box opens up main three areas 2. Select Fixed Support We all need to ASK for information to integrate efficiently. This is called the ASK system. Assembly Sub-assembly Kit

47. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Integration Fixed Support Assembly. wbs 1.04.03.08 B.O.M A.S.K. S.O.W Installation info

48. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Integration

49. Geoff Pile Single Undulator Test and Integration pileg@aps.anl.gov 12 th October2006 LCLSLCLSLCLSLCLS Integration Microsoft Access Links – P3 Information PARIS Procurement info Intralink Free form entry allows input from QAR CAMs & SLAC integration engineers.