PACMAN Project World Metrology Day€¦ · • accurate to measure form errors with 100 nm repeatability • maximum admissible weight of 1.2 kg ... First resonance = axis, Second

World Metrology Day

20 May 2016

PACMAN Project

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Outline

Introduction: presentation of PACMAN project [Hélène Mainaud Durand]

WP1: Metrology & alignment [Hélène Mainaud Durand]

WP2: Magnetic measurements [Stephan Russenschuck]

WP3: precision mechanics @ nano-positioning [Michele Modena]

WP4: microwave technology [Manfred Wendt]

Perspectives and conclusion [Hélène Mainaud Durand]

2Hélène Mainaud Durand, Michele Modena, Stephan Russenschuck, Manfred WendtMetrology day, 20 May 2016

PACMAN project

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PACMAN = a study on Particle Accelerator Components’ Metrology and Alignmentto the Nanometre scaleIt is an Innovative Doctoral Program, hosted by CERN, providing training to 10 EarlyStage Researchers.

Hélène Mainaud Durand, Michele Modena, Stephan Russenschuck, Manfred WendtMetrology day, 20 May 2016

Web site: http://pacman.web.cern.ch/

8 academic partners8 industrial partnersDuration : 4 yearsStart date: 1/09/2013

http://pacman.web.cern.ch/

Why PACMAN?

(1) introduction to CLIC project

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At 3 TeV: 20 000 modules, 2m length


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CLIC project: alignment strategy

Mechanical pre-alignment

Active pre-alignment

Beam based Alignment & Beam based feedbacks

One to one steering

Dispersion Free Steering

Minimization of AS offsets

Make the beam pass through

Optimize the position of BPM & quads by varying

the beam energy

Using wakefieldmonitors &

girders actuators

Beam on

Beam off

Minimization of the emittance growth

~0.2 - 0.3 mm over 200 m

14 - 17 µm over 200 m


Why PACMAN?

(2) State of the art

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Components to be aligned:

Number of components

Budget of error

~ 4000

~ 4000

14 µm 17 µm 17 µm

~ 140 000

Strategy:

BPM Quad AS AS AS AS

3 steps:

- Fiducialisation of the components and their support

- Initial alignment of the components on their support

- Transfer in tunnel and alignment in tunnel

BPM Quad AS


Why PACMAN?

(3) Example: case of MB quad + BPM


Pre-alignment sensors support

BPM

Quad

Stabilization Nanopositioning

Pre-alignment support

Quad

Stabilization Nanopositioning

BPM

Quad

Pre-alignment sensors support

Initial alignment: Transfer in tunnel & alignment

BPM

Fiducialisation:

Tunnel floor

• Strategy proposed for CDR in 2012. More than 20 000 assemblies!

• Accuracy achieved at that time: better than 15 µm over 140 m (mechanical reference axis) PACMAN project aims at improving that !

Objectives of PACMAN

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Combine references & methodsof measurements in the sameplace to gain time and accuracy

Prove their feasibility on a finalbench

Extrapolate the tools &methods developed to otherprojects

Some key issues:

• Upgrade of the magnetic measurements with a vibrating stretched wire (andalternative based on printed circuit boards rotating search coils)

• Determination of the electromagnetic center of BPM and AS using a stretched wire

• Development of absolute methods of measurements: new sensor for the measuringhead of the 3D Coordinate Measuring Machine (CMM), Frequency ScanningInterferometry (FSI) and micro-triangulation measurements as an alternative

• Design of seismic sensors to study ground motion

• Upgrade of the nano-positioning system to check the resolution of BPM


Management

Organization

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WP6 Diss & OutreachM. Modena

Supervisory BoardCERN,

HEXAGON METROLOGY, ETALON, ELTOS, METROLAB, DMP, SIGMAPHI, NIPISA univ., CRANFIELD, SANNIO univ., LAPP, ETHZ, IFIC, SYMME, Tech. Univ. of Liberec

WP0 ManagementH. Mainaud Durand

WP5 TrainingN. Catalan Lasheras

WP4 Microwave TechnologyM. Wendt

WP3 Precision mech. & nano-positioning

M. Modena

WP2 Magnetic MeasurementsS. Russenschuck

WP1 Metrology & Alignment

H. Mainaud Durand

Management team

Communication & admin. tasksT. Portaluri

WP1

Introduction


Objective of WP1: develop 3 methods to determine the positionof the stretched wire w.r.t. fiducials:- A high accuracy & touchless sensor on the CMM measuring head- Micro-triangulation - Frequency Scanning Interferometry (FSI)

WP1

CMM


CuBe wire characteristics Nominal values Sample 1 Sample 2

Electrical resistivity [µΩ/cm2/cm] 5.4 – 11.5 8.35, σ=0.02 10.86, σ=0.01

Limit tension [Kg] 0.5 – 1.3 1.176

Micro-hardness [Vickers] 100-362 357

Linear mass [mg/m] 64.80 66.34 65.97

Diameter [µm] 100 98.5, σ=1.4 99.2, σ=0.8

Form error circularity [µm] > 0.5

Roughness [nm] 20.9 9.7, σ=5.4

Characterisation of the CuBe wire:

Need of a rotary sensor

WP1

CMM


Design of a high precision, touchless and rotary sensor:

Requirements:

• accurate to measure form errors with 100 nm repeatability• maximum admissible weight of 1.2 kg• to have an opening• compatible with strong magnetic fields• low energy emission• non-contact measurements• can be inserted in the reduced space available on the bench

WP1

CMM


Choice of the measuring sensor:

Chromatic confocal technology• Repeatability measurements on a

0.1mm diameter steel gauge• 3 sensors from different providers

tested: σ from 96 to 112 nm• Other criteria considered like

integration, cost, delivery time

Next tasks:- Validation of all the components (optical

encoder, motor, sensor, air bearings)- Simulations to find the best parameters for

the rotation- Assembly of the stator and rotor- Test (first with no opening in the rotor)- Design of the final prototype

WP1

micro-triangulation


In collaboration with the Institute of Geodesy and Photogrammetryat ETH Zürich

• Eye-piece of a standard theodolite replaced by a CCDcamera (in a non destructive way)

• Automatic measurements of very accurate spatialdirections to visible targets (OTR mode)

• Hardware = theodolite + CCD camera + motorized focuser+ synchronization system + software (QDaedalus)

4 existing optical target recognitionalgorithms:- center of mass,- template least-square matching,- circle matching,- ellipse matching

Advantages:- Remotely operated- Touchless- Transportable- Non destructive- 3D accuracy better than 10 µm

WP1

micro-triangulation


Study of 2 algorithms: wire detection & wire reconstruction

Detection:• Edge detection (calculation of the axis after fitting in the two edges of the wire)• Main difficulties: filtering, edge extraction, line fitting, wire center extraction• Status: algorithms developed in Matlab

Reconstruction:• Based on least square adjustment analysis• Main difficulties: targets and wire measured in a unique coordinate system,

modeling of the wire, weighting the observations• Status: algorithms developed in Matlab

WP1

micro-triangulation


Next tasks:- cross-check measurements with the CMM to check the accuracy of the measurements- 2 new systems received to be validated- Synchronization of the 4 systems- Finalize the algorithms and their integration in the general software

WP1

FSI


Objective: perform multilateration measurements

WP1

FSI


• Totally free network

• 5 microns a priori standard deviation

• Solved with LGC++ (Least Squares method)

• 1000 simulations

• Based on Monte Carlo Method

• 8 FSI stations in total

• 4 FSI stations on each side

• 17 fiducials in total

• 3 fiducials can be seen by all 8 stations

• 7 fiducials per side seen by 4 stations

• No obstacles to line of sight

• 16 interstation observations

• 96 observations in total

According to these simulations, thecoordinates can be determinedwith the precision of theinstruments mounts (stations) andtargets (fiducials)

WP1

FSI


Next tasks:- Finish the simulations & freeze the configuration- Validate the concept of rotary station (and motorize it)- Integrate and design the FSI stations and fiducials on the PACMAN bench- Prepare the whole configuration (procurement, assembly, calibration etc.)

Combination of both systems:

Portable systemVery accurate measurementsAfter transport in tunnel of thecomponents or on the assemblylines

WP2:Magnetic

Measurements

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2.1 Stretched wire systems for magnetic measurement of small-aperture magnets

Domenico CaiazzaCERN supervisor: Stephan RussenschuckUniv. supervisor: Pasquale Arpaia

2.2Printed circuit board technology for small-diameter field probes.

Giordana SeverinoCERN supervisor: Marco Buzio

Univ. supervisor: Pasquale Arpaia

ESR2.1:Stretched Wire Systems for the Magnetic Measurement of Small-Aperture Magnets

Domenico Caiazza

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Flux linkage when the wire is moved from z1 to z2

in the complex plane

Easy result for movement on the horizontal plane

Stretched Wire Measurements: Classical, QuadrupoleGradients

Advances: Correction of the quadrupole strength when higher order multipole errors

are present


Domenico Caiazza

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Stretched Wire Measurements: Oscillating (out of resonance)Multipole field errors

Advances: Metrological characterization of phototransistors, CCD

sensors, and optical fiber sensors for measuring the peak-to-peak

oscillation amplitude


Domenico Caiazza

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Stretched Wire Measurements: Vibrating (resonance)Solenoid and quadrupolecenter and axis

Solenoid: First resonance = axis,Second resonance = center

Quadrupole: First resonance = centerSecond resonance = axis

Advances: Correction of background field (Earth magnetic field, tensioning motor etc.),

when placement at λ/4 and magnet rotation is not possible. Not for PM excitation.


Domenico Caiazza

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Stretched Wire Measurements: Vibrating (resonance)Longitudinal field profile and magnet positioning

Advances: Working at constant kinematic conditions instead of constant amplitude or wire-

excitation current.

ESR2.2:Printed circuit board technology for small-diameter field probes.

Giordana Severino

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Rotating Coil Measurements: Principles


Giordana Severino

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Rotating Coil Measurements: Problem of scaling to smaller radii andcalibration

Advances: In situ coil calibration when a sextupole component is present


Giordana Severino

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Advances: New positioning system, olive shape sapphire bearings (less vibrations)

PCB technology radial coils (no blind eye) with quadrupole compensation

Sapphire shaft (less sag)

Rotating Coil Measurements: New shaft design andproduction

WorkPackage 3

The WP3 covers the part of PACMAN studies dealing with Precision Mechanics

It include the activities of 3 ESR (Early Stage Researcher):

ESR 3.1 (I. Doytchinov, enrolled at Cranfield University (UK) PhD Program) on the study of the uncertainty budget, uncertainty propagation and study of possible uncertainty mitigation actions for the PACMAN assembly.

ESR 3.2 (P. Novotny, enrolled at Université de Savoie (F) PhD Program) on the improvement of existing vibration sensors and development of new one dedicated to the PACMAN requirements.

ESR 3.3 (D. Tshilumba, enrolled at TU Delft (NL) PhD Program) on the development of a dedicated nano-positioning system to be utilized for PACMAN components (i.e. quadrupole magnet) alignment.

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ESR 3.1: Uncertainty Budget Measurements

The main task is to provide a PACMAN Uncertainty Budget estimation according to GUM (Guide to the Expression of Uncertainty in Measurement as defined by BIPM (Bureau International des Poids et Mesures), http://www.bipm.org/en/publications/guides/gum.html).

More precisely the GUM Supplement 1 “Propagation of distributions using aMonte Carlo method” provide indication on how evaluate the measurementuncertainty based on propagation of probability distributions through amathematical model of measurement and its implementation by a Monte Carlomethod.

The evaluation by a Monte Carlo method is a practical alternative to the GUMuncertainty framework when:

- linearization of the model provides not adequate representation, or

- the probability density function (PDF) for the output quantity differs appreciably from a Gaussian distribution e.g. due to marked asymmetry.

This seems the case for the PACMAN magnet/BPM/measurements systems assembly.

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http://www.bipm.org/en/publications/guides/gum.html

Literature review (gaps of knowledge)

GAP 3 GAP 2 GAP 1

Gaps:

Uncertainty due

to fusing non

contact and

tactile probe for

length

measurements

Fiducials and

magnetic axis drift

due to

temperature

Uncertainty of

magnetic axis best

fit

(No conformance

to GUM and GUM

Supplement 1)

𝐷𝑟𝑖𝑓𝑡 = 𝐹 𝑇ℎ𝑒𝑟𝑚𝑎𝑙 𝑔𝑟𝑎𝑑𝑖𝑒𝑛𝑡, 𝑡𝑖𝑚𝑒

?

(Courtesy of I. Doytchinov)


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My plan is to mount two of the WPS non contact sensor kinematicly to the MBQ and use it to

measure the X, Y of the wire that my colague best fits every 20 minutes to the magnetic axis.

Figure 61: Example of the experimental setup for axis drift measurement

WPS Magnet

WPS

Marble base

Magnetic axis drift VS temperature measurements

Experimental design



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Stochastic Input parameters:

• Ambient temperature (Gaussian – 0.2 ºC SD)

• Coefficient of thermal expansion (Gaussian – 1E-06 µm/C/m SD)

• Convection Film Coefficient (Gaussian -2Wm^-2 ºC^-1 SD)

• Density (Gaussian – 20kg.m^-3 SD)

• MBQ temp measurement (Gaussian – 0.1ºC SD)



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ESR 3.2: Seismic sensor development and vibration characterisation

• The main objective is: To improve existing vibration sensors and/ordevelop a new one following the specific PACMAN requirements.

• The work is advancing mainly on:

a) Characterization of the state of the art sensors

b) Identification of a sensor to be developed for PACMAN

c) Manufacturing and characterization of the developed sensor.

d) Integration within the PACMAN bench.

Tight collaboration with Annecy on the sensor development

• Specific PACMAN case: how ground motion (GM) influences characterization of BPM ?

Seismic sensors

(Courtesy of P. Novotny)

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Which sensor for PACMAN?• Bandwidth = 0.1 ~ 200 Hz

• Resolution ≤ 0.1nm (RMS@1Hz)

• Magnetic fields resistance



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𝑅𝑀𝑆 = 𝑓1

𝑓2

𝑃𝑆𝐷 𝑓 × 𝑑𝑓

(the power spectral density PSD describes how power of the signal is distributed over frequency)


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The proposed new trasducer (3 in 1); the direct comparison should avoid data ambiguity

ESR 3.3: Nano-positioning system for PACMAN quadrupole magnet

(Courtesy of D. Tshilumba)

Coarse stage (cams)• locked after pre-alignment• Resolution : 0.35µm• Stroke: 3mm

Limitations: • ~50 days of operation using fine stage only• insuficient stroke of fine stage for thermal loadcompensation in tunnel ( >100 µm)• Limited precision of coarse stage

(1 µm achievable after severaliterations)

Upgrade of existing type 1 module + positioning controller design. Alternative concept for long range actuator

Fine stage (piezo stacks)• Resolution: 0.15nm • Stiffness : 480N/m • Useful Stroke: 10 µm

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Parameters Value

Resolution <0.25nm

step

displacement

0.25 up to 50nm

Stroke ± 3mm

Pitch angle 6rad

Yaw angle 6rad

Roll angle Max 100rad

Speed 50μm/s

Settling time t1-

>t2

10ms≤ts≤15ms

On-axis stiffness

(vertical/lateral)

400 N/μm

Force capacity

(positioning)

5N+20N

Force capacity

(isolation)

10N

Required functions :

5dofs Alignment (before beam)

2dofs Nanopositioning (beam-based alignment phase + nominal beam operation

phase)

2dofs Vibration isolation (nominal beam operation phase)

Stability requirements: • 1.5nm rms @ 1Hz (vertical)• 5nm rms @ 1 Hz (lateral)

Study of an integrated positioning system with high stiffness (>100N/m) capable of moving heavy loads (>50 kg) with high resolution (<1nm) over a large range (≥1mm) 38

(Courtesy of D. Tshilumba)CATIA V5 ANSYS WB

CA

D N

EXU

S

CAD parameters exchange and bi-directional update

Input parameters:• Remote magnet displacement (P2)• Notch hinges thickness (P4)• Diameter pillar (P5)• Fillet radius pillar (P6)• Notch hinges depth (P7)

Output parameters:• Equivalent Max stress (P1)• First eigen frequency (P3)• Vertical magnet displacement (P8)

Powerful tool for automatized sensitivity and optimisation study

2. side mode + bend1. Longitudinal + plate bend 1. Longitudinal mode 2 Side mode

Mode 1: 48.135 Hz Mode 2: 70.269 HzMode 3: 123.35 Hz

Mode 1: 91.6 HzMode 2: 117.2 HzMode 3: 167.14 Hz


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Activities done and ongoing:

Review and upgrade of the Type1 nano-positioning prototype

Positioning experiments and resolution measurement on type 1 prototype

Tools and techniques developed for the new design process :

Evaluate analytically the static stiffness and eigen modes of a compliant mechanisms in several dofs

Perform automatised sensitivity and optimisation studies of any CAD assembly (CATIA V5 + ANSYS WB)

Generate reduced MIMO state space model based on the FEM of any CAD assembly

Next steps:

Controller design for nano-positioning of type 1 module (Closed loop Vs Open loop)

Experimental comparative tests of positioning controllers with Speedgoat Real-time hardware (https://www.speedgoat.ch/)

Test bench design for proof of concept of long range nano-positioning actuator (mechanicaldesign, FEM-based optimisation, controller design, experimental validation)


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https://www.speedgoat.ch/

WP4:RF

Instrumentation and Technologies

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Characterization and alignment of the electromagnetic center of mission critical RF accelerator components:

15 GHz cavity beam position monitor (BPM)

12 GHz travelling wave accelerating structure (AS)

ESR4.1:Alignment of the Electrical Center of a 15 GHz Cavity Beam Position Monitor (BPM)

Silvia Zorzetti

Waveguide-loaded cavity BPM Beam excited resonant modes of the

cylindrical resonator

50 nm resolution potential of the symmetric structure

Electromagnetic center of the dipole mode

Imperfections due to mechanical tolerances

Causes an unwanted offset signal

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Silvia Zorzetti

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wire

VNA BPM

hexapod

down-

converter

LabVIEW

Stretched-wire S-parameter measurements

Performed at 15 GHz with a vector network analyzer (VNA)

BPM – stretched-wire moved near the mechanical center

Cross-coupling S21 analysis

First test results demonstrate a resolution of <1 μm

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Step size : 10um


Silvia Zorzetti

The 26 cell TW AS is used for beam acceleration 12 GHz fundamental accelerating mode

Unwanted higher order modes (HOM) are excited if the beam is off center or mechanical asymmetries

HOM analysis using waveguide couplers A stretched-wire is used as perturbation target in

connection with the VNA S-parameter analysis of the cross-coupling between wake-field couplers at the center cell 45

ESR4.2:Alignment of the Electrical Center of a 12 GHz Travelling Wave Accelerating Structure (AS)

Natalia Galindo Munoz

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Preliminary results of the stretched-wire measurements

Automatic LabVIEW-based search procedure

Resolution potential <1 μm

Investigate reproducibility

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401 pointsResolution: 1 µm

Measurement1Measurement2Measurement3Measurement4Measurement5

Resolution:1µmSpan:0.4mm

Resolution:1µmSpan:0.4mm

Next steps

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- Assembly foreseen beginning of June in ISR8- First measurements end of June in ISR8- Measurements in the metrology lab last week of July

Summary

PACMAN:

• Ambitious project to improve the precision & accuracy of the pre-alignmentof the CLIC components

• The solutions developed will be validated on individual test setups, beforebeing integrated in the PACMAN final validation bench

• The tools & methods will be extrapolated to other projects

This is the technical dimension of the project, but there is another dimension:

a high quality training program, with the aim to:

Train young

researchers in

topics of interest

for European

Industry

Improve the career prospects & employability of young researchers

Enhance

public-private

research

collaboration

Promote

science

Promote women in science

Disseminate the

results in the

private & public

sector

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PACMAN is a team work, it could not work without:

The students:• Claude Sanz• Vasileios Vlachakis• Solomon Kamugasa• Domenico Caiazza• Giordana Severino• Iordan Doytchinov• Peter Novotny• David Tshilumba• Silvia Zorzetti• Natalia Galindo Munoz

The CERN supervisors:• Ahmed Cherif• Jean-Christophe Gayde• Jean-Frédéric Fuchs• Stefan Russenschuck• Marco Buzio• Michele Modena• Andrea Gaddi• Kurt Artoos• Manfred Wendt• Nuria Catalan Lasheras

The academic supervisors:• Paul Shore• Paul Morantz• Markus Rothacher• Pasquale Arpaia• Paul Comley• Laurent Brunetti• Bernard Caron• Jo Spronck• Luca Fanucci• Angeles Faus Golfe

The industrial partners:• Jurgen Schneider, Norbert Steffens, Heinrich Schwenke, Marie-Julie Leray, Pascal Lequerre, Alicia

Gomez, Teun van den Dool, Augusto Mandelli, Jacques Tinembart, Philip Keller, Miroslav Sulc

CERN support:• Seamus Hegarty, Charlyne Rabe, Karen Ernst, Gregory Cavallo, Nicolas Friedli, David Mazur

PACMAN is a team work, it could not work without:PACMAN is a team work :could not work without:

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World Metrology Day

20 May 2016Thank you very much!

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Documents

PACMAN Project World Metrology Day€¦ · • accurate to measure form errors with 100 nm repeatability • maximum admissible weight of 1.2 kg ... First resonance = axis, Second