Undulator for the LCLS project – from the prototype to the full scale manufacturing

November 15-th, 2004 LCLS Undulator Final Design Review 1

XFD – XF Engineering GroupXFD – XF Engineering Group

Undulator for the LCLS project – from Undulator for the LCLS project – from the prototype to the full scale the prototype to the full scale

manufacturingmanufacturing



OUTLINE

Major Design featuresMajor Design features

Latest Design Changes (Latest Design Changes (Internal ANL Review - June 18, 2004 )Internal ANL Review - June 18, 2004 )

Long Lead ItemsLong Lead Items

Manufacturing ApproachManufacturing Approach

Major Design featuresMajor Design features

Latest Design Changes (Latest Design Changes (Internal ANL Review - June 18, 2004 )Internal ANL Review - June 18, 2004 )

Long Lead ItemsLong Lead Items

Manufacturing ApproachManufacturing Approach



PARTIAL LIST of LCLS UNDULATOR REVIEW

2003 Lehman Review (May 21-23, 2003) - Rockville, MD 2003 Lehman Review (May 21-23, 2003) - Rockville, MD LCLS Undulator Parameter Workshop - ANL - October 24, 2003 LCLS Undulator Parameter Workshop - ANL - October 24, 2003 Review of the LCLC Undulator - ANL - November 14, 2003 Review of the LCLC Undulator - ANL - November 14, 2003 LCLS Undulator Diagnostics and Commissioning Workshop - UCLA - LCLS Undulator Diagnostics and Commissioning Workshop - UCLA - January 19-20, 2004 January 19-20, 2004 LCLS Undulator System Review - ANL - March 3-4, 2004 LCLS Undulator System Review - ANL - March 3-4, 2004 Internal ANL Review - June 18, 2004 Internal ANL Review - June 18, 2004 External Independent Review - SLAC - June 7-11, 2004 External Independent Review - SLAC - June 7-11, 2004 LCLS Undulator Physics and Engineering Meeting - ANL - June 28-29, LCLS Undulator Physics and Engineering Meeting - ANL - June 28-29, 2004 2004 LCLS Undulator Meeting - ANL - July 23, 2004 LCLS Undulator Meeting - ANL - July 23, 2004 Lehman Review at SLAC - August 10-12, 2004 Lehman Review at SLAC - August 10-12, 2004

2003 Lehman Review (May 21-23, 2003) - Rockville, MD 2003 Lehman Review (May 21-23, 2003) - Rockville, MD LCLS Undulator Parameter Workshop - ANL - October 24, 2003 LCLS Undulator Parameter Workshop - ANL - October 24, 2003 Review of the LCLC Undulator - ANL - November 14, 2003 Review of the LCLC Undulator - ANL - November 14, 2003 LCLS Undulator Diagnostics and Commissioning Workshop - UCLA - LCLS Undulator Diagnostics and Commissioning Workshop - UCLA - January 19-20, 2004 January 19-20, 2004 LCLS Undulator System Review - ANL - March 3-4, 2004 LCLS Undulator System Review - ANL - March 3-4, 2004 Internal ANL Review - June 18, 2004 Internal ANL Review - June 18, 2004 External Independent Review - SLAC - June 7-11, 2004 External Independent Review - SLAC - June 7-11, 2004 LCLS Undulator Physics and Engineering Meeting - ANL - June 28-29, LCLS Undulator Physics and Engineering Meeting - ANL - June 28-29, 2004 2004 LCLS Undulator Meeting - ANL - July 23, 2004 LCLS Undulator Meeting - ANL - July 23, 2004 Lehman Review at SLAC - August 10-12, 2004 Lehman Review at SLAC - August 10-12, 2004



LCLS – general view



LCLS prototype undulator on the magnet LCLS prototype undulator on the magnet measuring standmeasuring stand



LCLS Prototype Undulator (major design features )LCLS Prototype Undulator (major design features )

1.Titanium housing made of forged 12” bar.1.Titanium housing made of forged 12” bar.

2. Base of the magnet structure sections made of aluminum alloy2. Base of the magnet structure sections made of aluminum alloy to partially compensate the changes in the magnetization of the permanent magnetsto partially compensate the changes in the magnetization of the permanent magnets with temperature.with temperature.

3. Only one clamp for each magnet is made of bronze.3. Only one clamp for each magnet is made of bronze.

4. Incremental shims or might be used for the undulator gap adjustment.4. Incremental shims or might be used for the undulator gap adjustment.

5. Out-bond area is completely open for the side shims to tune the field5. Out-bond area is completely open for the side shims to tune the field strength along the undulator.strength along the undulator.

6. Side shims have four bars made of low carbon steel. Each bar can 6. Side shims have four bars made of low carbon steel. Each bar can be individually adjusted and locked in place.be individually adjusted and locked in place.

7. Five cam-shaft movers are used for alignment of the undulator as a whole.7. Five cam-shaft movers are used for alignment of the undulator as a whole.



LCLS Undulator Latest Design ChangesLCLS Undulator Latest Design Changes

1. Canted undulator design (wedged shims) – proposed by Joachim Pflueger1. Canted undulator design (wedged shims) – proposed by Joachim Pflueger

2. Housing has provision for “magnetic needles” and alignment targets.2. Housing has provision for “magnetic needles” and alignment targets.

2. Simple pole design with two clamping screws from the bottom.2. Simple pole design with two clamping screws from the bottom. 3. Outside fixture for the pole installation.3. Outside fixture for the pole installation.

4. New side shim design to decrease fringed field.4. New side shim design to decrease fringed field.

5. New cam-shaft mover deisgn. 5. New cam-shaft mover deisgn.

6. Magnet structure base made as a single block (three parts before)6. Magnet structure base made as a single block (three parts before)



LCLS undulator with wedged shims LCLS undulator with wedged shims (canted)(canted)



LCLS prototype undulator magnetic LCLS prototype undulator magnetic structure with two pole clampsstructure with two pole clamps



LCLS magnetic structure (old and new)LCLS magnetic structure (old and new)

Implementation of the new design can save about $20K - $25K per undulator



LCLS magnetic structure base – new designLCLS magnetic structure base – new design

Implementation of this new design can save about $4K - $5K per undulator



LCLS magnetic structure with a single unit LCLS magnetic structure with a single unit basebase



LCLS undulator pole assembly fixtureLCLS undulator pole assembly fixture



Fixture for the Magnet Structure Fixture for the Magnet Structure AssemblyAssembly



LCLS Prototype Undulator Titanium HousingLCLS Prototype Undulator Titanium Housing



LCLS Prototype Undulator magnetic needle test set-upLCLS Prototype Undulator magnetic needle test set-up



LCLS Undulator Housing Design ChangesLCLS Undulator Housing Design Changes Manufacturing simplificationManufacturing simplification

1. Counterbore clamping holes instead of counterbore groves.1. Counterbore clamping holes instead of counterbore groves.

2. No provisions for phase shifters. 2. No provisions for phase shifters.

3. Central grove for vacuum chamber location is removed.3. Central grove for vacuum chamber location is removed.

4. More simple provisions for the support pads. 4. More simple provisions for the support pads.

Improvements for more precise alignmentImprovements for more precise alignment

1. Housing has provision for “magnetic needles” on both ends.1. Housing has provision for “magnetic needles” on both ends.

2. Housing has provisions for four sets of alignment targets. 2. Housing has provisions for four sets of alignment targets.



LCLS Undulator PoleLCLS Undulator Pole

Material: VACOFLUX 50

(vanadium permendure)

Quantity: PER UNDULATOR - 450 TOTAL - 19200

TOTAL WEIGHT: ~ 5300 lbs



LCLS Undulator MagnetLCLS Undulator Magnet

Material: N39UH

(Nd-Fe-B type magnet )

Quantity: PER UNDULATOR - 450 TOTAL - 19200

TOTAL WEIGHT: ~ 10900 lbs



• Design of the undulator itself is ready for manufacturing, Design of the undulator itself is ready for manufacturing, • Design of the undulator support cradle and all associated Design of the undulator support cradle and all associated

motions is 2005 year task. Nevertheless we can’t see its motions is 2005 year task. Nevertheless we can’t see its impact on housing design. Some minor changes in the impact on housing design. Some minor changes in the support area location can be easily corrected during the support area location can be easily corrected during the manufacturing – manufacturing – we have time;we have time;

• It is not necessary to work with only companies, who It is not necessary to work with only companies, who

have undulator experience, our choice of vendors is quite have undulator experience, our choice of vendors is quite wide; wide;

• We are going to teach and train selected vendor We are going to teach and train selected vendor (vendors) how to assemble magnetic structure of LCLS (vendors) how to assemble magnetic structure of LCLS undulator and how to put it inside housing. Detailed undulator and how to put it inside housing. Detailed procedure is written and necessary fixtures are designed.procedure is written and necessary fixtures are designed.

Manufacturing approachManufacturing approach



ConclusionConclusion

• Prototype of the LCLS undulator was successfully designed, Prototype of the LCLS undulator was successfully designed, manufactured, tuned, and tested;manufactured, tuned, and tested;

• Multiple changes in the design of the prototype wereMultiple changes in the design of the prototype were implemented, tested in the preparation for the full scaleimplemented, tested in the preparation for the full scale production, and approved by internal design review ;production, and approved by internal design review ;

• Forty Forty undulators will be manufactured in the next three years; undulators will be manufactured in the next three years;

• Procurement package for the long lead items (strong back, Procurement package for the long lead items (strong back, magnets and poles) is 98% ready;magnets and poles) is 98% ready;

• We would like to have one LCLS undulator each two weeks. We would like to have one LCLS undulator each two weeks.

Undulator for the LCLS project – from the prototype to the full scale manufacturing

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