LIU Wire Scanner Production Readiness Review
29 March 2017
INDICO: https://indico.cern.ch/event/618262/
Present:
Federico Roncarolo, Lars Jensen, Jose Sirvent, Malika Meddahi, Giovanni Rumolo, Jonathan Emery, Patrik Andersson, Jose Somoza, Benoit Salvant, Klaus Hanke, William Andreazza, Thibaut Lefevre, Dimitry Gudkov, Nicolas Chritin, Jocelyn Tan, Bettina Mikulec, Alessandro Dallocchio, Alexandre Mariet, Emilien Rigutto, Stephen Jackson, Christine Vollinger, Thomas Kaltenbacher
Scope (Ray):
Questions to be addressed in this review
Is the mechanical design satisfactory and ready to proceed for series production?
Do we have confidence that this instrument will fulfil the specification for LIU?
Do we have confidence that the instrument:
Will be qualified for vacuum acceptance?
Will not have a major impact on machine operation due to impedance?
Should not suffer wire breakage due to impedance heating?
Is the series budget and schedule understood and are the costs justified?
Mechanical Design (Dimitry)
New design to address issues/limitations with existing scanners:
Motion is transferred through crank mechanism
Bellows for motion transfer
Inaccuracies due to the relatively complex mechanics (crank-slider mechanism)
High deformation of forks during movement
Polymer materials used in mechanism design
Custom Helicoflex flange and seal
Initial SPS prototype needed to be improved in terms of:
Weight and size (wasn’t designed for the PSB)
Non-standard ConFlat flange (DN400)
Optical encoder components are inside the vacuum volume
Drum-based design, complicated and expensive for production
New design in close collaboration with IWG, TE-VSC, EN-MME
2 main components - vacuum tank & kinematic unit
Kinematic unit the same for all machines
Only fork size & position on shaft changes
4 variants of vacuum tank
H&V for SPB, PS & SPS
Geometry optimised for UHV - pumping holes included for all possible trapped volumes
Design approved by VSC
Reliability
SPS prototype tested to 75000 cycles with no degradation observed
Long term tests to over 100000 cycles foreseen for 2nd PSB prototype
Components
Stepped chamber - most complicated mechanical part to produce
Requires electron beam welding
Optical encoder
Glass disk currently used, but favoured solution is LESS Al disk
Forks
3D additive Ti manufacturing - tested for vacuum compatibility - OK from VSC
Status
SPS & PSB scanners installed
Integration
PSB H&V - underway with 3D drawings to be prepared
Looks to be interference between SEM grid on ring 3
ACTION: BI-ML to check integration of SEM grid & WS for PSB
PS & SPS - 3D integration complete
Mechanical Production (William)
Tanks - MS & IT required
Documents prepared & meeting with spec committee done
Aim - contract signed 3rd quarter 2017
Delivery 1st quarter 2018
Stepped chamber
Price enquiry for machining with EB welding at CERN
Delivery 1st quarter 2018
Mechanical components
Procurement handled by MME for ~2500 parts
Delivery 1st quarter 2018
Supports
Design ongoing, price enquiry MME
Delivery 3rd quarter 2018
Motor
Single tender (ALXIOM) with price request submitted
Delivery 4th quarter 2017
Vacuum Acceptance (Jose)
Mechanical components - Individual tests - all OK
RGA of full system
Issues after cleaning/assembly required to repeat the process
Origin of contamination not fully understood
Cleaning and assembly of different components is critical
Co-axial Kapton cable
Identified as main outgassing item
Diffusion of water in very thin Kapton® layer
Bakeout with subsequent exposure to air does not help long term outgassing
Only helps when bakeout in situ
For PSB
FWS out of spec at 24h but in spec at >300h
Summary
Once exposed to air Kapton re-absorbs water so no improvement in pumpdown rate
With ion pump added even current Kapton cable OK for PSB & SPS
Not OK for PS
Need ion pump & change of wire
VSC recommendation to add ion pump & change of wire for PS
Retrofit cable on all scanners if suitable replacement found
Expected Performance (Federico)
Wire position determination
Old system
Rotational WS: Relies on calibration tables
Linear : direct use of potentiometer
New system
Beam size: inferred from angular position from optical disk - no calibration required
Beam positon (offset) : still requires calibration
Sources of uncertainty for beam size measurement
Wire position uncertainty
Optical disk
10urad precision and reproducibility
Translates to error < 1.5 um
Mechanical plays
Fork deformation
Wire vibration
Acquisition electronics
Detector
Acquisition
Fit routine
SPS Prototype Coasting Beam Results
270GeV with PMT down to 1.5 spread in measurements
12um sigma on ~800um beam size
Compared to 22um for linear scanner
400GeV pulsed with single bunch
12um on beam centroid
107nm! on beam size
ACTION:
BE-BI to provide a table summarising wire position uncertainty & calibration test bench results
Comments regarding results from calibrations:
Comments regarding scope for use in the SPS:
Impedance (Christine)
PSB - simulations & measurements:
Simulations compared to probe-probe measurements and probe-coupler measurements
2 strong modes simulated & measured at 812 MHz & 867 MHz
Well above beam spectrum
Effective impedance negligible
Simulations for SPS & PS:
Effective impedance also found to be negligible
Conclusion: no visible showstopper expected from transverse or longitudinal impedance
Wire heating
Highest induced power observed at 523 MHz and 882 MHz at 135 deg position
PSB expect no influence (above beam spectrum)
PS 0.01 W/turn from 874MHz mode at 0 degree (parking)
SPS
0.11 W/turn from 523 MHz mode at 0 degree (parking)
1.98 W/turn from both modes at 135 degree
Need to check units!!
Heating will depend on interaction with beam modes
With ferrites will always interact, i.e. heat
Without ferrites will depend on mode frequency
No ferrites therefore preferred as long as modes are not hit
ACTIONS:
Bench measurement with real wire (ACTION: Impedance WG with help from BI)
MD with high intensity in SPS
Possibility to instrument SPS prototype wire with higher frequency readout (ACTION: BE-BI in collaboration with Impedance WG)
Cost & Schedule (Ray)
Unit costs for production:
Material + vacuum tank & chambers + instrument + support
57 kCHF/ instrument
Control Electronics + Acquisition system
23.5 kCHF/ instrument
Cabling average
33.4 kCHF/ instrument
Budget:
1258 kCHF for series production
780kCHF for cabling, vac interface, remaining design
133kCHF for assembly & calibration benches
2.2MCHF TOTAL BUDGET for installed scanners
1.3MCHF remaining in EVM
0.9MCHF additional required
Spares - 280kCHF
Options - 308kCHF
Summary
Decision on go-ahead needed or mechanics early May for tendering to start mid-May
VSC OK
Impedance OK
Mechanical performance to be finalised
LIU needs input on final expected mechanical performance by end April
MAIN ACTIONS:
BE-BI to produce table of precision uncertainty for mechanical system and address the comments regarding calibration and scope for use in the SPS.
LIU management to see how additional costs can be covered in discussion with CONS
BE-BI to organise follow-up meeting end of April to present & discuss this table