C. Boffo E. Borissov H. Carter Fermilab, Technical Division RF Technology and Development Group F. Le Pimpec A. Seryi C. Adolphsen SLAC T. Khabiboulline FNAL C. Boffo Slide 1/27
OUTLINE Strongbacks for NLCTA Delivered (FXB002/3/4) Near future plans (FXB005/6) Linac Girders development Stability Measurements Vibrations FEM/FEA Movers HLS Schedule & Budget C. Boffo Slide 2/27
Strongbacks For NLCTA Delivered FXB002/4 on strongbacks with instrumentation Delivered FXB003 on strongback Only few changes in the supports design. Working on an interface document for FXB006 and FXCs C. Boffo Slide 3/27
OUTLINE Strongbacks for NLCTA Delivered (FXB002/3/4) Near future plans (FXB005/6) Linac Girders development Stability Measurements Vibrations FEM/FEA Movers HLS Schedule & Budget C. Boffo Slide 4/27
Stability measurements (SM) C. Boffo Slide 5/27
SM LCW Manifolds Thermocouple Pressure gauge SOURCE RETURN Flowmeter Structure Girder Solenoidal Valve Pressure gauge Thermocouple Connect the instrumentation to the DAQ code in Labview (additional DAQ card) in order to monitor: Pressure, Temperature and Flow of the LCW, and Ambient Temperature C. Boffo Slide 6/27
SM LCW Connections GIRDER Pressure drop: Flow 4.5gpm ~ 0.28 l/s DP ~90psi (measured) Re = 30000 (turbulent) F = 0.006 (von Karman) L = 14.4m ( 1.8 x 2 str.) DP ~ 8psi STRUCTURE Change fittings to lower pressure drop C. Boffo Slide 7/27
SM Alignment Vertical Horizontal C. Boffo Slide 8/27
SM Calibration 60 50 Calibration - Micrometer reading 49 mm 53 µm BPM Displacement [ mm] 40 30 20 10 0 0 2 4 6 8 10 BPM Normalized Position Micrometer [µm] DAQ Before [µm] DAQ After [µm] 51 56 51 102 112 102 Repeatability within 1 mm 201 215 195 C. Boffo Slide 9/27
SM DAQ Controls Average Mid points Temp End points C. Boffo Slide 10/27 Link for remote monitor: TDPC157.fnal.gov
SM Measurements 90 88 Temperature Girder T Structure T 86 Temperature [ F] 84 82 80 78 Position mm 76 74 72 0 200 400 600 800 1000 1200 1400 1600 Time [min] Position [µm] 5 4 3 2 1 0-1 -2 0 100 200 300 400 500 600 700 800 900 1000 Time [min.] C. Boffo Slide 11/27 Middle BPM Positions LCW T in 87.0 F LCW T out 86.5 F Ambient T ~65.0 F Flow on Structure 4.5 gpm Flow on Strongback 6.8 gpm P in 150 psi 30 psi P out
SM Measurements 90 Temperature 89 Temperature [ F] 88 87 86 85 Girder T Structure T Position mm 84 Position [µm] 83 0 50 100 150 200 250 300 Time [min] 18 17 16 15 14 13 12 0 50 100 150 200 250 300 Time [min] C. Boffo Slide 12/27 Middle BPM reading LCW T in 87.0 F LCW T out 86.5 F Ambient T ~65.0 F Flow on Structure 4.5 gpm Flow on Strongback 6.8 gpm Pin 150 psi Pout 30 psi
Temperature [ F] 84 82 80 78 76 SM Measurements Horizontal Temperature Girder T Structure T Position [µm] 1.5 1 0.5 0-0.5-1 Middle BPM Positions Mockup in MP8 74-1.5 72 0 50 100 150 200 250 300 350 400 450 500 Time [min] -2 0 50 100 150 200 250 300 Time [min] 10 0-10 Middle BPM Positions A Position [µm] -20-30 -40 BPM 2 BPM 3 BPM 4 BPM 5 BPM 6 BPM 7 B -50-60 BPM 8 BPM 9 BPM 10 BPM 11-70 0 50 100 150 200 250 300 350 400 450 500 Time [min] C C. Boffo Slide 13/27
SM PLANS Acquire long term measurements on both vertical and horizontal planes Try to implement dummy structures in the setup Use the information acquired to design supports for the structures for the NLC girder C. Boffo Slide 14/27
OUTLINE Strongbacks for NLCTA Delivered (FXB002/3/4) Near future plans (FXB005/6) Linac Girders development Stability Measurements Vibrations FEM/FEA Movers HLS Schedule & Budget C. Boffo Slide 15/27
Vibrations We started performing vibration measurements and analysis, but we are still on the learning curve. We are ready to begin vibration measurements on a strongback with 2 dummy structures connected to the MP8 LCW. C. Boffo Slide 16/27
Vibrations C. Boffo Slide 17/27
Vibrations C. Boffo Slide 18/27
Vibrations FEA 61 Hz 75 Hz Ansys models of 2 structures on a strongback are being optimized. Modal analysis is being performed and compared with real assembly. C. Boffo Slide 19/27
OUTLINE Strongbacks for NLCTA Delivered (FXB002/3/4) Near future plans (FXB005/6) Linac Girders development Stability Measurements Vibrations FEM/FEA Movers HLS Schedule & Budget C. Boffo Slide 20/27
Motors and movers Control unit 8 units to PC C. Boffo Slide 21/27
Motors and movers 0.8 Step length 0.6 mm 0.4 0.2 0 0 1000 2000 3000 4000 5000 Steps 200 steps per turn on motor 100:1 ratio of gearhead 20000 steps on the cam Eccentricity 0.141 in. 3.58 mm mm 2500 2000 1500 1000 500 0 Motion Profile 0 1000 2000 3000 4000 5000 Steps C. Boffo Slide 22/27
OUTLINE Strongbacks for NLCTA Delivered (FXB002/3/4) Near future plans (FXB005/6) Linac Girders development Stability Measurements Vibrations FEM/FEA Movers HLS Schedule & Budget C. Boffo Slide 23/27
Hydrostatic Level System Contract with BINP to buy 4 sensors plus software. Delivery expected for end of July and commissioning by the end of August 2003 COSTS: Sensors (4) $ 2,500 / each Software $ 5,000 $15,000 C. Boffo Slide 24/27
SCHEDULE C. Boffo Slide 25/27
SUMMARY Due to funding constrains in FY03, Linac girder R&D has proceeded more slowly than we would have liked, but we are addressing the MAC guidelines by starting some FEA modeling of structures on strongbacks for modal analysis. Data on thermal stability are being acquired, while vibration measurements are still part of the learning curve at FNAL. A moving support with 2 DOF is being assembled right now. An order for 4 HLS sensors has been placed We continue to support the FNAL structures delivery to SLAC for testing in NLCTA and the 8 Pack test. C. Boffo Slide 26/27
PLANS Our aggressive plan, still assuming that this is a low priority project and all the contributors are involved in other activities, is to complete this stage by the first quarter of 2004 and start designing a prototype of NLC like girder in February 2004 C. Boffo Slide 27/27