Transcript Undulator Vacuum System

Undulator System
Components Status
Dean Walters
June 17, 2008
Undulator System Components
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D Walters
[email protected]
Undulator System Components Status
Components
Vacuum Components
Chamber
Quad Spool
Bellows
EVAC Flanges
Diagnostics
RFBPM
Beam Finder Wire
Beam Loss Monitor
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D Walters
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Vacuum Chamber
End bi-metal flange welding
From:
E Trakhtenberg
G Weimerslage
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D Walters
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Vacuum Chamber
Graphical Display of Surface finish Data
Z' and X' Data of Delivered Chambers
The average of all vacuum
chambers is 14.86 mrad in Z′
and 35.14 mrad in X′, the rms
of Z’ is 15.5 mrad and X’ is
36.9 mrad. Selecting the best
33 chambers yields an rms
for Z’ of 13.9 mrad and X’ of
34.2 mrad. Extrusions 7, 10,
16, 28 and 35 were sacrificed
to verify surface finish in the
middle of the extrusions
25
Should be Avoided
20
Acceptable
15.5
Z' (mrad)
15
Series1
10
Very Desirable
5
From:
E Trakhtenberg
36.9
G Weimerslage
0
0
10
20
30
40
50
60
X' (mrad)
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D Walters
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Quad Spool
Design
Flexible mini-bellows
Surface finish measurements of the central tube show a roughness of Sq=.18 µm
Issue with aluminum plating covering the seal face of the EVAC flange, the vendor has addressed this
during the course of the production run.
Fifteen units have now been shipped
The production run is due to be complete by the end of June
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D Walters
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Bellows Module
Initially the supplier had problems with the welding of the SST adapter
to the flange. The supplier solved the problem by using the micro-TIG
welding process.
All (35) units have assembled, baked, packaged, and shipped to SLAC.
The last group went to SLAC on 6 June 2008
June 17, 2008
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D Walters
[email protected]
EVAC Flange System
Flange Permeability
Flanges from the manufacturer have been found
to have a high (1.21) magnetic permeability.
Testing has shown that while the permeability is
high it will not interfere with devices in the
beamline.
Flange Sealing Experience
SLAC has started to assemble girders and has
had to make vacuum seals using EVAC Flanges.
Their initial results have been good and bad.
One thing that has been seen is that the pits in the
copper gaskets are thought to be a source of
leaks.
ANL is now inspecting all gaskets for pits before
sending to SLAC.
SLAC is experiencing what ANL went through
before consistent results were achieved.
Through testing at ANL it was found that lubrication
of the chain clamp is important, ANL is using
Dicronite lubricate on all chains in the Undulator
Vacuum System.
June 17, 2008
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D Walters
[email protected]
BFW Assembly Mounted on Adjustable Support
Electrical Connectors
for Wire Signals
Potentiometer
Pneumatic Solenoid Valve
Compression Spring Positioner
Air Supply Shut Off Valve
Precision Screw
Card Position Monitor
(Limit switches)
Frame
Housing
Alignment Fiducials
Pneumatic Cylinder
(Modified since) Vacuum
Pump Connector (2.75”
Conflat Flange)
Vacuum Chamber Connection
Flange
(NW-50 CeFix w/Clamp)
Assembly model courtesy: J. Bailey, ANL
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Beam Port
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Adjustable Mounting
Support
D Walters
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Moving Slide Assembly (Solid Body)
Electrical Connector and
Feedthrough
Secured to Slide Rod
Kinematic Stop Top Plate
Fixed to Frame
(Adjustable using precision
Screws)
Top of Return Spring
Fixed to Frame
Kinematic Stop
Bottom Plate
Secured to Slide
Block
Slide Block
Secured to Slide Rod
Cylinder Bore
Fixed to Frame
Card Mount Block
Secured to Slide Rod
Assembly model courtesy: J. Bailey, ANL
June 17, 2008
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D Walters
[email protected]
Revised Design
Precision
Screws
Spring
Loaded
Positioner
Frame
Locking Screw with
Lock Washer
Precision
Screw
Clearance
between slide rod
and frame
Top Kinematic
Plate attached to
Frame
Assembly model courtesy: J. Bailey, ANL
June 17, 2008
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D Walters
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Beam Finder Wire
Repeatability Testing
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D Walters
[email protected]
BFW Repeatability Test Arrangement and Results
Physics Requirements: 65 Micron Horizontal & 30 Micron Vertical (RMS)
“Keyence” Displacement Sensors (Typ.)
Repeatability Test BFW S#04
Sensor Readings
Pt. A
Pt. B
Displacement
(Microns)
10
0
-10
0
20
40
60
80
100
-20
Pt. C
-30
Cycles
Repeatability Test BFW S#04
Calculated Displacements at Card Centerline
Horizontal
Displacement
(Microns)
30
20
Vertical
10
0
-10
0
20
40
60
80
100
120
Cycles
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Repeatability Test Arrangement
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D Walters
[email protected]
Production of the BFW
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D Walters
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Vacuum Conditioning
June 17, 2008
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D Walters
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Beam Finder Wire Status and Schedule
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D Walters
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RFBPM Production
Altair End Caps
Production End Caps are in spec
electrically and mechanically
Problems with polishing resolved
Production ramping up with 10 sets first
received 4/22/08
LCLS BPM End Caps #1
Measuremen
t
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LCLS BPM End Caps
#2
RMS
(nm)
Sa
(nm)
PV
(nm)
RMS
(nm)
Sa
(nm)
PV
(nm)
1
21.9
17.3
411
45.7
30.6
2066
2
23.5
18.6
659
48.6
32.5
1898
3
23.6
18.9
548
43.0
29.4
1674
4
23.9
18.7
433
47.9
33.2
1880
Average
23.2
18.4
513
46.3
31.4
1880
D Walters
[email protected]
Single Piece Transitions
Solder Joint Considerations
Order of Joining
K2
Au-Cu
K1
K1
Au-Ge
Au-Sn
Strongest Design
Order of Joining
K1
K2
Au-Sn
Au-Ge
Sn-Ag-Cu
Au-Sn
Au-Ge
H2
H2
Sn-Ag-Cu
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Undulator System Components
This allows windows to
be jointed, tested, and
selected before joining
to the cavity body.
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K2
Au-Sn
Au-GE
H2
Au-Sn
D Walters
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Sn-Ag-Cu
Joining Window to Transition
Use of a Moly ring limits the expansion of the
copper which then limits the compression of
the glass window.
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D Walters
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Brazing Fixture
This is the body mounted in the fixture for
joining the Transitions to the Body
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D Walters
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RFBPM Windows QC Results
June 17, 2008
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D Walters
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Monitoring Windows Quality
Windows Process Chart
12
10
9
8
7
8
6
6
5
4
4
No. of Defects
Thickness (mils)
10
Minimum
Maximum
Average
Defects
3
2
2
1
0
0
8
9
10
11
12
13
14
15
Group Number
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D Walters
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Repair of Soldered Assembly
June 17, 2008
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D Walters
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BPM Window Statistics
Transition and window
soldered with Georo filler
material
Sub Assemblies are
Vacuum checked before
brazed to body
In the last run of windows
being brazed to transitions
there were 11 of 13 defect
free parts made.
Transitions are soldered
with Orotin to the bodies
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D Walters
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RFBPM Status and Schedule
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D Walters
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Beam Loss Monitor
Beam Line Detector:
Detailed and Assembly Drawings:
(engineering review and tolerancing).
Detector Head.
Detector BFW Mounting Bracket.
Undulator Motion Tracking Adapter.
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D Walters
[email protected]
Conclusions
Except for the Beam Loss Monitor all other components are
in production
Items that have completed production
Vacuum Chamber
Vacuum Chamber Support
Beam Finder Wire Support
BPM Support
Bellows Module : Final Unit 6/6/08
Items still in the process of production
BPM cavity - (36% complete) : Final Unit 7/31/08
Beam Finder Wire - (45% complete) : Final Unit 7/8/08
Quad Spool - (45% complete) : Final Unit 6/24/08
Long Break Spool and its support : Final Unit 6/18/08
June 17, 2008
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D Walters
[email protected]