Intra Girder Assembly and Alignment Robert Ruland

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Intra Girder Assembly and Alignment Robert Ruland

• Alignment Philosophy
• Assembly and Alignment

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Alignment Tolerances

• Two primary alignment tolerances
• All quadrupoles need to be aligned to within 2
  µm to a common reference line.
• All undulator segments need to be aligned to this
  reference line within 80 µm vertical and 140 µm
  horizontal.
• BPM and vacuum chamber need to be aligned to the
  reference line within
• the following tolerances
• BPM horizontal 200 microns
• BPM vertical 200 microns
• Vacuum Chamber horizontal 200 microns
• Vacuum Chamber vertical 200 microns
• Quadrupole alignment tolerance will be achieved
  using Beam-based-alignment (BBA).
• For BBA to converge the quadrupoles need to be
  aligned using conventional alignment methods to
  100 µm uncorrelated and 200 µm correlated

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Undulator to Quad AlignmentTolerance Budget
Individual contributions are added in quadrature
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Alignment and Support Philosophy

• Global alignment of undulator segments over
  entire length to 80 (60) µm is very tough,
  instead will use BBAligned quads as local
  alignment references for undulator segments
• 60 µm tolerance is reduced from global (130 m
  length) to relative (girder), i.e. one undulator
  segment to its adjacent quadrupole
• To avoid having to perform the critical relative
  alignment under tunnel conditions, all components
  are mounted onto a common girder. The common
  platform retains the relative alignment when
  moving the quadrupole in the BBA process

• Alignment Sequence
• Fiducialization of Components
• Intra Girder Alignment
• Conventional Installation Alignment
• Beam-based-alignment (Quadrupole and loose end)

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Girder Alignment Concept

• All components will be available as complete
  sub-assemblies
• Girder
• Motion systems
• Manually adjustable supports
• Beam steering / detecting components undulator
  segment, quad, BPM, BFW
• Vacuum components undulator vacuum chamber,
  misc. components
• All components will have been fiducialized
• Undulator segments, quadrupoles and BFW will have
  fiducials in each of the principle planes
• RF-BPM is referenced by precision surfaces
• Girder Coordinate System
• Undulator segment in nominal position determines
  the girder axis
• All 33 undulator segments will have identical
  axis offsets variation in location of magnetic
  centerline wrt mounting feet is taken out by
  individual shims during fiducialization
• All other components are aligned to this axis

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Girder Assembly Alignment

• Carried out in two steps
• Assembly in girder factory (Bldg 650?) No
  temperature control
• Mechanical installation of components
• Rough alignment sufficient for vacuum
  connections
• Vacuum connections
• Plumbing Wiring
• Alignment in MMF ( 1º K temp. control)
• Pre-alignment (Optical Tooling, Faro Arm)
• Final alignment (CMM Zeiss or Faro)

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Girder Assembly Alignment Sequence (1)

• Girder Assembly in Bldg 650
• Station 1 Prepare Girder
• Mount cam wedges underneath girder
• Station 2 Component Installation
• roll-away slides
• component supports
• HLS WPM components
• undulator vacuum chamber
• rough-align vacuum chamber
• Station 3 Vacuum
• install, pre-align and connect quad with
  inserted chamber
• same for BFW and BPM
• same for misc. vacuum components
• Station 4 Wiring / Plumbing

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Girder Assembly Alignment Sequence (2)

• Girder Alignment in MMF (temperature controlled)
• Station 1 Optical Alignment Faro Arm
• align vacuum chamber
• install undulator
• check undulator to vacuum chamber clearance
• align undulator to X0
• pre-align girder components wrt undulator
• remove undulator
• Station 2 CMM (Faro Arm or Zeiss)
• install undulator
• align all components wrt undulator
• align undulator to Xi
• remove undulator
• If test measurements prove that the combination
  of optical alignment and Faro arm can provide the
  required final alignment accuracy, all girder
  alignment will be performed at Station 1. The
  Zeiss CMM is already fully loaded by
  fiducialization measurements.

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In Situ Intra-girder Alignment Verification

• We will be able to verify the relative component
  alignment in situ
• Horizontal component alignment tolerance (125 µm)
  can be achieved with standard methods e.g.
  optical tooling, ecartometer (CERN developed wire
  offset meter)
• Vertical component alignment tolerance (60 µm) is
  marginally within optical leveling range. To be
  safe, we are planning to build a portable HLS
  based on the existing ultrasound sensors

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END of Presentation