ESR 3.1 IntroductionIordan Doytchinov

26.05.2014

Contents: Who am I

My MEng degree

Industrial Placements and University Projects

PACMAN project 3.1 I) Optimization of the Design and Assembly of the Main Beam Quadruples (MBQ)

for the CLIC Two Beam Modules – PhD thesisII) Mechanical Integration of the PACMAN Assembly/Alignment Bench

Current work plan, Training

To do..

Me:

I come from here - Sofia Beside Engineering…

Integrated Engineering MEngElectrical

Engineeringtraining

Mechanical Engineering training

Mechanical Design and Materials Selection

Thermal and Fluid Mechanics

Vehicles Dynamics

Electronic Devices & Circuits

Control Engineering

Electromagnetic Fields and Waves

Core/Integrated Subjects

Mechatronics

Robotics Engineering

Complex Interdisciplinary projects Engineering and Design

Systems modeling/simulation

Industrial Placements Projects/MEng Thesis

Siemens – Test automation - 1 year F4E – Vehicle Dynamics/ Performance - 3 months

National Met Office UK:UAV Performance Estimation /system Integration

Omron ltd Barcelona:Real-Time HIL robot dynamics simulator (Master THESIS)

PACMAN 3.1 - ObjectivesI) Optimization of the Design and Assembly of the Main Beam Quadrupoles (MBQ) for

the CLIC Two Beam Modules - main for PhD Hypothesis

II) Mechanical Integration of the PACMAN Assembly/Alignment Bench

“If you grasp the principles – myths fall & Ideas take-off” David Lentink (TUDELFT) TED

Conference Amsterdamخليفة “) Khalifa Tower“) – Dubai" ,برج2010

Babylon tower by Tobias Verhaecht (1561 – 1631)

One off prototype example: Dominique Loiseau - the Rose de Temps clockExtremely costly on time & money

High number production (thousands): ‘Swatch’ mass production of Swiss made high quality wrist watches

I) Optimization of the MQQ Design & AssemblyOptimize magnet mechanical-magnetic design and assembly procedure from point of

view of ultra precision engineering.

Good Field Region (GFR) Specification:

- R(GFR) = 4mm

- = 0.1%

Component design

Assembly procedure/jig (easy, cheap, fast)

Quadruple Yoke prototype example By Raphael Leuxe

Beam Dynamics magnetic field Spec

The desired function! Our Meca!

Understand relationship?

Field Spec VS Mechanical/Assembly spec

Quadruple Yoke prototype example By Raphael Leuxe

“There is not such thing as bad ‘function’ delivered by assembly/component. All functions are ‘perfect’ and acts according to its intentional or unintentional design.

There is only a ‘bad’ or not well understood design.”

Understanding of real material geometry as function of environment and itself (temperature, gravity, coupling forces).

‘Right’ Kinematic design (restriction of the right degrees of freedom)

The insurances of the ‘right’ measurement met

Design for repeatability. (high stiffness design – low histersis, attenuation due thermal, vibration effects).

Other..

The Precision Engineering View

Understanding of the ‘scale’ of the problem. Internship in Metrology department – Accuracy, Uncertainty, Resolution, Repeatability, Reproducibility and Tractability of micrometric measurement at 2m length scale. The same activity to be performed at DMP Spain!

Understanding of the current state of art – Assembly with mounting key design.

Investigation of perfect possible mechanical assembly from CMM measurement of prototype parts (KOTEM software)

Understanding of beam dynamics specification in the contexts of mechanical specification (Daniel Schulte), FEA magnet Simulation software, KOTEM

Material selection for the magnet? Investigation on best material for point of view of magnetic and high precision mechanical design (Ashby analysis)

Current Tasks for I)

II) Mechanical Integration of the PACMAN Assembly / Alignment Bench

• Specifications coordination (by Iordan Doytchinov): Act as system engineer making sure all the subgroups specification Integrate in appropriate way: QFD analysis to be performed as practice for wire integration case study - Understanding of the complete specification

Possible Ashby analysis for selection of hybrid material for the wire.

• A GLOBAL mechanical/assembly INTEGRATION aspect (by Iordan Doytchinov) BPM sensor mechanical alignment and integration to MBQ magnets

- BPM integrated with beam pype? - BPM as part of the MBQ? - Other solution such as separate stand or integration to MBQ stand

II) Mechanical Integration of the PACMAN Assembly / Alignment Bench

• A GLOBAL mechanical/assembly INTEGRATION aspect (by Iordan Doytchinov)

Electromechanical integration of magnetic, RF and metrological wire measuring tools into single one (one wire, one stretching system)1 Wire and support structure for 2 to 4 different measurements: (RF BPM, RF ACC structures, MBQ Magnetic field position and quality, Metrological reference )

II) Mechanical Integration of the PACMAN Assembly / Alignment Bench

• A GLOBAL mechanical/assembly INTEGRATION aspect (by Iordan Doytchinov)

To perform the full mechanical integration of the prototype alignment bench (which will fit on Leitz CMM) make sure all sensor, control actuators systems integrate electromechanically. All ultraprecision design techniques to integrate various subsystems into the final PACMAN stand

Current Work Plan, Training Current work:

Study Assembling of DMP prototypes with mechanical KEY method developed - Use KOTEM smart fit software (http://www.kotem.com/Pages/SmartFit.htm) to study best fit of components

Wire integration case study for 2x systems (Magnetic and Metrological). Practice QDF (Quality Function Deployment) and component analysis to select appropriate wire and stretching systems.

Training:So far 3day basic ISO GD&T course; 1 day Faro arm course To do: - 10 Day CATIA course - 6 Day ANSYS course - Internship Metrology department, - High Precision engineering course at Cranfield

- Other

To Do

Identify Risk Metrics and redesign work/training plan with accordance to it:

Create detailed work, training plan, define Scientific Hypothesis on Part I

Thank you for listening

Your feedback?

“CUSTOMERS”:

Magnetic measurement

Mechanical Measurement

RF Measurement BPM

RF Measurement Acc structures

QFD

Ashby analysis Hybrid Material