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LCLS Undulator Controls Status

LCLS Undulator Controls Status. July 11, 2007 Josh Stein - LCLS Undulator Controls Technical Lead Outline of presentation Technical update and challenges Budget and cost performance Schedule update and status. Power Supplies.

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LCLS Undulator Controls Status

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  1. LCLS Undulator Controls Status • July 11, 2007Josh Stein - LCLS Undulator Controls Technical Lead Outline of presentation • Technical update and challenges • Budget and cost performance • Schedule update and status

  2. Power Supplies • 33 Sets of Quadrupoles with Integrated X-Y Corrector Magnets require power • Correctors may not be powered initially • BiRa MCOR Power Supplies • Off the shelf product, used in PEP-II and Spear • Use 6 Amp supplies with standard fault status indicators, readback and reset control • Deployed in standard SLAC configuration • An MCOR crate contains 16 power modules, therefore 3 crates will be required • Long-haul cables ordered, rack profiles being reviewed

  3. Power Supply Status • MCOR Components • Ordered, some have arrived • Bulk supplies which drive the system are here • Other Components • Racks, CPUs, VME modules are here • VME crates will be ordered within 30 days • PLC system for magnet protection has partially arrived • Schedule • Racks will be populated in October • Testing will start soon after that

  4. CAM Actuator calibration fixture • Completed June, 2007 • Enables Undulator Assembly vendor to calibrate the cams and align the rotary potentiometers • Easily followed procedure for rapid and verifiable determination of cam maxima, minima and profile used for coefficients to the motion algorithms • These parameters are integral to the motion algorithms used by the control system

  5. CAM Actuator calibration fixture

  6. Undulator Control Module • Primary design challenge for the APS team • Responsible for: • Undulator motion control • Temperature measurement • Beam-Finder-Wire actuator control • Preliminary Design Review conducted on :May 21, 2007 • See included PDR handouts • Committee report found nothing significantly lacking in the design or implementation of the UCM (report is included in appendix)

  7. UCM: Design outline • UCM must reside in the half-height rack within the undulator hall • As such, vertical height became a design constraint • Hytec Blade IOC (with various IP-modules) chosen as the commercial platform • Custom interface chassis being designed in-house to convert SCSI hi-density connectors to field devices • Includes additional electronics including: • Bridge circuitry for RTD measurements • Comparator interlock for translation stage motion • DC Power supply for motors

  8. UCM: Motion Control • Animatics “smart” motors specified • Motors are serial based devices - one port per motor (7 per undulator) • Five motors responsible for the position of the Undulator via CAM movers • Two motors responsible for linear translation of the Undulator in/out of beam center • Position read-back via precision potentiometers • Rotary potentiometers connected to each CAM to verify angular position • Linear potentiometers attached to a variety of places on the undulator assembly to determine position of both the girder (via the cam movers) and the undulator strongback (via the translation movers)

  9. UCM: Motion Control Software • Most challenging design problem within the UCM • Complex motion algorithm (developed by Joe Xu) determines proper motor commands to perform a move • Currently system runs ‘semi-closed loop’ with no feedback from position potentiometers • Decisions need to be made on which ‘layers’ of software APS will deliver to the LCLS - include OPI screens • Low level engineering software includes: • Raw (per motor) move instructions • Middle level software might include: • Motion of a given point on the girder (typically the quad) in 2 dimensions • Performing a ‘scan’ in one plane to leverage the BFW diagnostic

  10. UCM: Motion Control challenges • At present, the known position of a particular CAM is tightly coupled to the specific rotary potentiometers connected to it • How can we replace a failed potentiometer in-situ? • Can the calibration procedure be performed in-tunnel? • At present the motion software runs in a ‘semi-closed-loop’ fashion • The motor counts are verified as being performed to assure the move request is honored • None of the absolute positioning devices are used to feed-back to the motion system • If necessary it is possible to integrate the position detectors within the motion control loop • Rough calculations suggest that the time allotted for a given move would exceed that of the PDR

  11. UCM : Software deliverables • What type of API does LCLS want from the APS design team? • Presently we are working with 3 different layers of abstraction • Low level (motor counts) • Middle level (CAM degrees) • High level (Quad position in X/Y) • Nobody on the UCM design team feel that any of these challenges are insurmountable

  12. UCM: Other responsibilities • Translation stage interlock comparator • Used to assure the two translation stages move in a coordinated fashion • Platinum 3-wire RTDs used for temperature measurements • Achieves relative temperature measurements within 0.5°C for long-term stability trend analysis • BFW Control • Digital I/O for moving BFW in or out of the beam (with limit-switch readback) • Analog input to determine positional accuracy (via linear potentiometer) of inserted BFW assembly using same type of linear potentiometer as the undulator position read back

  13. Undulator Controls design and procurement budget • Re-baseline exercise allowed us to bring our budget closer to realistic numbers • Impact of CR in 2007 is negligible for most of the UCM and ancillary components as we were in a pure design phase during most of Q1FY07 • As per project guidelines, no contingency is held ‘locally’, however all estimates are recent and we have a high-level of confidence that we will deliver within budget

  14. Undulator Controls budget update • Large procurements have been put out for: • Motors • Cable Components • Linear and Rotary potentiometers • Still to be purchased • Blade IOC controller assemblies (awaiting FDR) - See delivery concerns • UCMI assemblies (awaiting FDR) • EIA and cable assemblies (released to procurement) • Other infrastructure items are being purchased by SLAC (networking, racks, long-haul cables)

  15. Out for bid: • 35 Different types of intra-undulator cables designed • Allows rapid connection of field devices (position potentiometers, RTDs, BFW, etc) to IOC • Award expected by the end of July; First articles expected by mid-August. • Electronics Interface Assembly design complete • Aluminum channel assembly used to route wiring from undulator components to equipment rack • Fabrication being done at ANL - expected complete mid August, 2007

  16. UCM: Blade IOC Delivery concerns • Minor concern on delivery of 35 Blade IOCs in time for commissioning • Alternative design has been proposed using LCLS approved VME crates and modules • Cost difference is negligible • Schedule impact? • Need to determining a ‘drop-dead’ date to accept Blade IOC design so the schedule is not at risk due to vendor delivery problems

  17. Delivery Procedure • Equipment racks will be fully populated before shipping to SLAC • A traveler will accompany each rack • The same procedure will be followed for the EIA and cable assemblies • Uncrating, checkout and assembly procedures will be written as appropriate

  18. Undulator Controls Schedule Update • A large exercise was completed to integrate the entire Undulator controls schedule into one WBS under 1.4.2 • All subsystems from both labs (SLAC and ANL) are now covered within 1.4.2 • Vestigial tasks were removed or “zeroed” • Structure changed to correspond to the rest of the project; integrating more technical content under level 4 sections • Technically the schedule is now much more accurate and easier to track

  19. Undulator Controls WBS elements • 1.4.2.8 : Magnet Power Supplies • Primary Engineer: Kristi Luchini (SLAC) • Procurement and installation of magnet power supplies • Software support • 1.4.2.10 : Undulator Control Module • Primary Engineer: Steven Shoaf (ANL/APS) • Design, procurement and delivery of the undulator control module • Includes software design • 1.4.2.12 : Rack and cable • Primary Engineer: Rich Voogd (ANL) • Specification of all intra-undulator and long haul cables • Specification and procurement of in-tunnel and service building racks • 1.4.2.13 : RFBPM Testing support • Primary Engineer: Steven Shoaf (ANL/APS) • Responsible for assisting in the testing of the RFBPM design at APS

  20. Undulator Controls WBS elements (continued) • 1.4.2.14 : Long Term Test • Primary Engineer: Joe Xu (ANL/APS) • Specification of the long-term test controls setup • Specification and design of the undulator CAM testing fixture • 1.4.2.20 : Machine Protection System • Primary Engineer: Stephen Norum (SLAC) • Specification, design and procurement of the undulator hall machine protection system • 1.4.2.21 : Timing • Primary Engineer: Stephen Norum (SLAC) • Specification and installation of the timing sub-system within the undulator hall • 1.4.2.22 : BPM • Primary engineer: Till Straumann (SLAC) • Specification of the controls interface to the RF Cavity BPMs including the A/D hardware and lower-level applications • 1.4.2.23 : Vacuum • Primary engineer: Stephen Schuh (SLAC) • Interface to the vacuum components within the undulator hall • 1.4.2.24 : ADS • Primary Engineer : TBD (SLAC) • Interface to the alignment diagnostic system to allow EPICS access to the alignment data

  21. Major schedule milestones • UCM • FDR July,2007 (will slip) • Award Blade IOC contract August, 2007 • Award First article UCMI November, 2007 • Receive final UCMI February, 2008 • Populated racks ready for ship to SLAC March, 2008 • Intra-undulator cable contract • Award contact July, 2007 • Receive final shipment September, 2007 • Electronics Interface Assembly • Receive final delivery September, 2007 • SLAC Installation • Begins March 2008

  22. Staffing update • The APS has delivered on the promise to make the LCLS a high priority by reducing APS workload on various staff people to allow them time to work on LCLS tasks • APS Controls has committed various people in support of the Undulator Control System • Currently all APS activities in support of the LCLS Undulator Controls project are staffed

  23. ANL/APS Staff in support of Undulator Controls • Josh Stein - Technical Lead • Steve Shoaf - UCM Chief designer • Rich Voogd - Cable and raceway design • Joe Xu - Algorithm design • Robert Laird - Electronics design • Stan Pasky - Procurement and vendor liason • Eric Norum - Technical consultant • Ned Arnold - Technical and managerial support

  24. End of presentation

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