PACMAN Project World Metrology Day€¦ · • accurate to measure form errors with 100 nm...
Transcript of PACMAN Project World Metrology Day€¦ · • accurate to measure form errors with 100 nm...
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
Why PACMAN?
(1) introduction to CLIC project
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At 3 TeV: 20 000 modules, 2m length
Hélène Mainaud Durand, Michele Modena, Stephan Russenschuck, Manfred WendtMetrology day, 20 May 2016
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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
Hélène Mainaud Durand, Michele Modena, Stephan Russenschuck, Manfred WendtMetrology day, 20 May 2016
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
Hélène Mainaud Durand, Michele Modena, Stephan Russenschuck, Manfred WendtMetrology day, 20 May 2016
Why PACMAN?
(3) Example: case of MB quad + BPM
7Hélène Mainaud Durand, Michele Modena, Stephan Russenschuck, Manfred WendtMetrology day, 20 May 2016
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
Hélène Mainaud Durand, Michele Modena, Stephan Russenschuck, Manfred WendtMetrology day, 20 May 2016
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
10Hélène Mainaud Durand, Michele Modena, Stephan Russenschuck, Manfred WendtMetrology day, 20 May 2016
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
11Hélène Mainaud Durand, Michele Modena, Stephan Russenschuck, Manfred WendtMetrology day, 20 May 2016
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
12Hélène Mainaud Durand, Michele Modena, Stephan Russenschuck, Manfred WendtMetrology day, 20 May 2016
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
13Hélène Mainaud Durand, Michele Modena, Stephan Russenschuck, Manfred WendtMetrology day, 20 May 2016
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
14Hélène Mainaud Durand, Michele Modena, Stephan Russenschuck, Manfred WendtMetrology day, 20 May 2016
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
15Hélène Mainaud Durand, Michele Modena, Stephan Russenschuck, Manfred WendtMetrology day, 20 May 2016
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
16Hélène Mainaud Durand, Michele Modena, Stephan Russenschuck, Manfred WendtMetrology day, 20 May 2016
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
17Hélène Mainaud Durand, Michele Modena, Stephan Russenschuck, Manfred WendtMetrology day, 20 May 2016
Objective: perform multilateration measurements
WP1
FSI
18Hélène Mainaud Durand, Michele Modena, Stephan Russenschuck, Manfred WendtMetrology day, 20 May 2016
• 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
19Hélène Mainaud Durand, Michele Modena, Stephan Russenschuck, Manfred WendtMetrology day, 20 May 2016
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
ESR2.1:Stretched Wire Systems for the Magnetic Measurement of Small-Aperture Magnets
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
ESR2.1:Stretched Wire Systems for the Magnetic Measurement of Small-Aperture Magnets
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.
ESR2.1:Stretched Wire Systems for the Magnetic Measurement of Small-Aperture Magnets
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
ESR2.2:Printed circuit board technology for small-diameter field probes.
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
ESR2.2:Printed circuit board technology for small-diameter field probes.
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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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)
ESR 3.1: Uncertainty Budget Measurements
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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
(Courtesy of I. Doytchinov)
ESR 3.1: Uncertainty Budget Measurements
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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)
(Courtesy of I. Doytchinov)
ESR 3.1: Uncertainty Budget Measurements
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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
(Courtesy of P. Novotny)
ESR 3.2: Seismic sensor development and vibration characterisation
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(Courtesy of P. Novotny)
𝑅𝑀𝑆 = 𝑓1
𝑓2
𝑃𝑆𝐷 𝑓 × 𝑑𝑓
(the power spectral density PSD describes how power of the signal is distributed over frequency)
ESR 3.2: Seismic sensor development and vibration characterisation
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ESR 3.2: Seismic sensor development and vibration characterisation
(Courtesy of P. Novotny)
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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(Courtesy of D. Tshilumba)
ESR 3.3: Nano-positioning system for PACMAN quadrupole magnet
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
ESR 3.3: Nano-positioning system for PACMAN quadrupole magnet
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(Courtesy of D. Tshilumba)
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)
ESR 3.3: Nano-positioning system for PACMAN quadrupole magnet
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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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ESR4.1:Alignment of the Electrical Center of a 15 GHz Cavity Beam Position Monitor (BPM)
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
ESR4.1:Alignment of the Electrical Center of a 15 GHz Cavity Beam Position Monitor (BPM)
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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ESR4.2:Alignment of the Electrical Center of a 12 GHz Travelling Wave Accelerating Structure (AS)
Natalia Galindo Munoz
Preliminary results of the stretched-wire measurements
Automatic LabVIEW-based search procedure
Resolution potential <1 μm
Investigate reproducibility
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ESR4.2:Alignment of the Electrical Center of a 12 GHz Travelling Wave Accelerating Structure (AS)
Natalia Galindo Munoz
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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