Advanced Photon Source Upgrade Project: Alignment Strategy … · 2018-07-27 · Advanced Photon...
Transcript of Advanced Photon Source Upgrade Project: Alignment Strategy … · 2018-07-27 · Advanced Photon...
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Advanced Photon Source Upgrade Project: The World’s Leading Hard X-ray Light Source
Alignment Strategy for APS Upgrade
Project
Jaromir M. Penicka Survey and Alignment Section APS Engineering Support / Mechanical Engineering and Design Argonne National Laboratory International Workshop on Accelerator Alignment Grenoble, October 3-7, 2016
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Outline
APS-U Overview Team Requirements and Tolerances Floor Stability and Control Networks Support and Alignment System Magnet Mapping and Fiducialization DMM Prototype Testing Summary
2 J.M. Penicka - IWAA2016 Grenoble – October 3-7, 2016
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Advanced Photon Source today
Built in 1990s Commissioned
in 1995 66 Operational
beamlines 5000+ users
annually
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Third generation 7 GeV light source
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APS Upgrade
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“APS-U exceeds the capabilities of today’s storage rings by 2 to 3 orders of magnitude in brightness, coherent flux, nano-focused flux.”
APS Today (3rd generation)
APS Upgrade (4th generation)
Double-Bend Lattice
Multi-Bend Achromat Lattice
Stuart Henderson, Project Director
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APS Upgrade organization
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Contributor Acknowledgement
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Support Structures & Alignment Systems Design
Jeff T. Collins Curt Preissner Jeremy Nudell Zunping Liu Scott Izzo Nate Poindexter Bill Turner Mike Bosek
Magnet Design & Magnetic Measurement
Mark Jaski Chuck Doose Jie Liu Roger Dejus
Survey & Alignment
Rolando Gwekoh Bill Jansma Keith Knight Kristine Mietsner
Mechanical Integration Herman Cease
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Survey and Alignment Tolerances
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Parameter value unit
SR Circumference 30 mm
Girder to girder alignment 100 µm rms
Magnet to magnet 30 µm rms
Dipole tilt 0.4 mrad
Quadrupole tilt 0.4 mrad
Sextupole Tilt 0.4 mrad
APS survey control networks Survey measurements Alignment with respect to networks
Survey measurements No control network constrains Relative alignment / smoothing
Mechanical design Machining tolerances Magnetic measurements
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APS-U Storage Ring Sector
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Forty sectors with nine module assemblies of four types
o Two quadrupole doublets: two quadrupoles and a fast corrector on each o Four longitudinal gradient bending magnets o Two straight multiplets: four quadrupoles, three sextupoles, one fast corrector on each o One FODO: four quadrupoles, three Q-bends and one 3PW source on each
Modules will be installed in the Storage Ring as assembled complete units.
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Physical constrains of the storage ring walls
Reuse of existing infrastructure (value>$1B)
Intimate knowledge of building behavior (22 years of settlement data)
Existing survey networks
Retrofitting Existing Facility
J.M. Penicka - IWAA2016 Grenoble – October 3-7, 2016
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Original SR Horizontal Control Network
J.M. Penicka - IWAA2016 Grenoble – October 3-7, 2016
σZ,X < ±0.30mm
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SR Horizontal Control Network Today
J.M. Penicka - IWAA2016 Grenoble – October 3-7, 2016
• Verify and densify existing network
• Constrain optimal number of original points
• Global tolerance achievable (30 mm circumference)
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APS Settlement History
J.M. Penicka - IWAA2016 Grenoble – October 3-7, 2016
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Rate of Settlement
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Settlement rate • 0.45 mm/year first decade • 0.09 mm/year second decade
Worst single points over 22 years • 6.51 mm total settlement • 0.86 mm total uplift
Girder Adjustment Range ±13 mm
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Up to 36 mm of grout Up to 36 mm of grout
Survey of Storage Ring Floor Elevations
Detail Sector 18 Floor Elevations
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Typical Support Structures & Alignment Systems Design
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1. Three-point vertical wedge jack supports with spherical bearings and slip plates to decouple translation and rotation from the vertical motion
2. Lateral pushers to provide lateral and yaw constraint and alignment while decoupling vertical motion
3. Longitudinal pusher to provide longitudinal constraint and alignment while decoupling vertical motion
4. Support outriggers (3 total) to provide 6 DOF for plinth alignment prior to grouting
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1 1 2
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4 Design features:
• Semi-kinematic 6 DOF alignment systems • Reinforced concrete plinth • Ability to pre-load wedge jack supports • Ability to lock down magnet support
structure during transport
Multiplet section during transport
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Support Structures & Alignment Systems Design
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FODO section
• Wedge jacks used for all lateral pushers • Aisle side adjustments for all alignment features • Topology optimization software (GTAM) used to
design cast magnet support structure (girder) • Girder optimized to maximize fundamental
frequency and minimize static deflection along the beam path
Geometry input to GTAM software
Geometry output from GTAM software
Manufacturable geometry for foundry
Optimization courtesy Zunping Liu
Mass: 29,000 kg Footprint: 6.5m x 0.9m
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Concrete Plinth Dimensional Stability Monitoring
• Plinths effectively raise the floor • The continuous welded steel frame and proprietary
concrete mixture help minimize distortion • Concrete was poured on 3/27/2015 • Less than 20 µm of shrinkage has been measured
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DMM Assembly and Measurement
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• Initial alignment of the magnets on the girder rely on machining tolerances of the mating parts
• Rotating wire magnet mapping • Shimming based on magnet
mapping data • 1-2 iterations (45 min. per iteration )
Mag. measurements courtesy Chuck Doose
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DMM Fiducialization Tests
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Leica AT930 rotating wire circle measurements
2500 dynamic points 13 stable points
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DMM Transportation Tests
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Final X-alignment 5.5 microns rms
Repeatibility 5 microns per magnet
Mag. measurements courtesy Chuck Doose
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Summary
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Survey and Alignment involved in the preliminary design phase of the project. QC of component hardware, helping define design parameters, testing of prototype support and adjustment systems, fiducialization and magnet mapping a better design that will be easier to implement.
Substantial progress made on preliminary designs of the support structures and alignment systems.
Several prototypes have been built and tested, many in procurement.
Identified approaches and methodology for meeting alignment tolerances. Identified directions for survey and alignment R&D to validate them.
The solution for the most challenging 30 microns components within girder tolerance looks very promising.
Approach validated by DMM tests, more work has to be done on optimization of this process and testing the effects of thermal changes, transportation, and long term storage on the stability of alignment.
Identified need to start developing a database for S&A data and a model for alignment data flow for the project.
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Thank you for your attention!