13/09/2012 1

CLIC Permanent Magnet Quadrupole

Engineering Development update

Norbert Collomb, STFC Daresbury Laboratory

N. Collomb

13/09/2012 2

CLIC Permanent Magnet Quadrupole

• First part of presentation:– Progress since last meeting– Assembly images– Next steps– Summary

• Second part of presentation:– Second family member– Principle decision for further

development– Summary

N. Collomb

13/09/2012 3

CLIC Permanent Magnet Quadrupole• Since last meeting 27/06/2012 much progress

– Procurement complete– Test plan1 and specification2 complete– Phase two assembly complete (re-setting required)– Identified issues– Disassembly and resetting complete– Unit dowelled– Motor change complete (brake replace with rotary encoder

to verify and validate motion – back driving not an issue due to gearing and ballscrew)

– Optical Linear encoder mounted and tested– Final re-assembly in progress

• 1 clic-pmq-meng-tpl-001_V1b.docx• 2 clic-pmq-meng-tsp-001_V1.docx

N. Collomb

09/08/2012 4

Phase 2 measurement set-up

N. Collomb

Probe inserted

Outer limit switch

Inner limit switch

Optical Linear Encoder

Cables everywhere Need to seriously tidy up and identify routes.

13/09/2012 5

Next step (1): Final Assembly• Side-plate assembly to core in progress (today)• Insertion of Permanent Magnet cap (tomorrow)• Alignment and motion testing (early next week)• Linear encoder assembled and aligned• Final measurements• Motor – Gearbox assembly electronic integration• Linear encoder head assembly and adjustment• Progress (pictorial) documented in CLIC PMQ Portfolio.pptx

Expected duration:

Max 1 week + 1 week contingency

N. Collomb

13/09/2012 6

Second Assembly – Rework

N. Collomb

Rotary encoder to double check linear encoder and as a solution to the “encoder per unit request”.

Same motor specification

Encoder connector

13/09/2012 7

Second Assembly – Rework

N. Collomb

Rotary indicator with minute gradation

Inclinometer “spirit” level

One degree gradation indicator

The horizontal (table top) has been measured (reference datum) with the core aligned to it.

The inclinometer shows a true angle between the two surfaces of 100° and 4’ between 1 and 3.Surfaces 2 and 4 show an angle of 99° 53’.

Variation between the “dot face” (depicted) and opposite side is 2’ changing linearly.

Inner Face plate – yoke proposed dowel pin location. Midpoint of Yoke fastener holes.

Core re-assembled after skimming wedge contact surfaces.

Inscribed radius ‘measured’ and found correct.Diameter now within 10 micron.All yoke edge gaps within 25 micron.

13/09/2012 8

Second Assembly – Rework

N. Collomb

Brass slip gauge diameter: 27.198 mm

‘Old’ Dowel holes

New Dowels New, slightly longer dowels used.Dowels secured into yoke steel instead of yoke wedge (aluminium).

Core ‘clamped’ to square and placed on level parallels to ensure angular accuracy is achieved.

13/09/2012 9

Second Assembly – Rework

N. Collomb

Dowels in both sides in case magnet needs to be split (i.e. insert vacuum chamber).

Dowels in Yoke wedges for the same purpose as mentioned above. Aids in the precise ‘re-assembly by eliminating all 6 degrees of freedom.

13/09/2012 10N. Collomb

Far side Bench side

1 3

2 4

←9.028→

←9.029→

↑9.04

↓

↑9.056

↓

Diagonal measurements:1-4: 27.1852-3: 27.208Delta: 0.023

Diagonal measurements:1-4: 27.2052-3: 27.200Delta: 0.005

1 F 3 F

2 F 4 F

←9.11→

←8.993→

↑9.04

↓

↑9.03

↓

Design value (H/V):9.03

Core only measurements taken after unit had been re-assembled, the ‘wobble’ or play is extremely small and disappears when the brass slip gauge is ¾ to fully inserted.

← M

inute

play

→←

Minute play →

Difference can’t be explained without precise measurement of chamfers.

13/09/2012 11

Next step (2): Phase 2 testing (repeat)• Test motor – gearbox – ballscrew motion (static

and dynamic test)• Test linear encoder and limit switches (adjust if

required)• Identify datum and create motion map• Insert assembly into test stand and align• Perform tests to specification• Create field map

Expected duration:

Max 1 week + 1 week contingency

N. Collomb

13/09/2012 12

CLIC PM Quadrupole summary• The core assembly process is straight forward and some deviations between

the first and second measurements proved to be negligible with regards to the results – expect much closer agreement with current assembly

• A first step has been taken towards semi-automated assembly of core components – methodology revised in light of re-assembly

• Initial manufacturing investigations indicate that the core can remain as the current design

• Re-dowelling of inner faceplate was required + side dowels introduced

• Back driving did not occur, hence brake not required

• Delivery to CERN still planned for end of September 2012 (unit leaving Daresbury)

N. Collomb

13/09/2012 13

CLIC Permanent Magnet Quadrupole

Second family member

Norbert Collomb, STFC Daresbury Laboratory

N. Collomb

27/06/2012 14

CLIC PM Quadrupole T2 - recap• Investigated a number of different movement principles• Had a meeting to decide on principle to be developed further• Iterations are underway between mechanical design and magnetic

design• Some alterations to initial basic shape already carried out• Had meeting with motor and gearbox manufacturer• Encoder can be incorporated (provisionally) in gearbox• Brake can be incorporated in motor• Linear motion system identified (need to include this in magnetic

model)• Will provide a CAD model for integration purposes soon (4 weeks)• Still require separate vertical and horizontal corrector• Once more detail is known create project plan

• Progress made since then on following slides

N. Collomb

27/06/2012 15N. Collomb

CLIC Permanent Magnet Quadrupole T2• CAD Model (re-cap)

Shroud, shell or casing (180x380x380mm)

Permanent Magnet (180x70x37.2mm)

Yokes (180x108.4x55.4mm)

Visual inspection:

“Floating” yokes need to be restraintPermanent magnets require mechanismShell halves need to be “connected”Alignment of shell – core constraints a mustAll items need to fit into envelopeForce reversal (63 – 70mm stroke)Friction ‘force’ to be added to magnetic force

27/06/2012 16N. Collomb

CLIC Permanent Magnet Quadrupole T2• CAD Model (last meeting status)

Shroud

Face-plate

Re-circulating linear bearings

Left and Right Hand Threaded Ball-screw

Connecting bracket

Permanent Magnet frame

Yoke Nose-pole Connecting Flange

Linear Motion Shaft with flanged bushing

Envelope check

13/09/2012 17N. Collomb

CLIC Permanent Magnet Quadrupole T2• CAD Model

Shroud changed

Re-circulating linear bearings moved further out (Magnetic modelling influence)

Connecting bracket provisional suggestion

Permanent Magnet frame alteration

Yoke Nose-pole Connecting Flange

Envelope check

13/09/2012 18

CLIC PM Quadrupole summary• Strong version:

– High strength version final re-assembly in progress– Assembly and measurements carried out concurrently– Initial indications are promising (Ben’s 2D error model)– On target for completion for delivery end of Sept. 2012– Phase 2 measurements to commence latest next week– Deliver to CERN (unit leaving Daresbury date: end of September latest)

• ‘Weak’ version– Overall principle agreed to develop further– Magnet modelling to be re-done with current CAD sketch– Detailing to commence after integration check– Process concurrent to strong version completion

• Comments– Meeting at CERN (2 days proposed, one 11 October, one 25 October)

N. Collomb