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EDMS N° 1209791

EDMS N° 1209791. Dimensional control and fiducialisation of TM1 CLIC girder n°DB02E Measurements performed the 29th of March 2012, metrology lab. Introduction. Summary: End of 2010: dimensional control of the 2 Epucret girders on manufacturing site using laser tracker (EDMS n° 1103377 )

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EDMS N° 1209791

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  1. EDMS N°1209791 Dimensional control and fiducialisation of TM1 CLIC girder n°DB02E Measurements performed the 29th of March 2012, metrology lab.

  2. Introduction Summary: • End of 2010: dimensional control of the 2 Epucret girders on manufacturing site using laser tracker (EDMS n° 1103377 ) • End of 2010: Receipt measurements at CERN using laser tracker (EDMS n° 1108177) • March 2012: machining of V-Support at CERN • Mid of March, 2012: Romer arm measurements without load  several tenth of misalignment but no big fault was detected. • End of March: CMM measurements performed according to the drawing n°CLIATLSS0065 and instructions from Nick Gazis and from SU team (for the future, a drawing which meets the needs will be useful). Objectives of CMM measurements: • to accurately evaluate the misalignment of V-supports and so to decide if a new machining or an adjustment is needed, • To fiducialise the girder mean axis.

  3. Measurement conditions • Coordinate Measuring Machine: OLIVETTI Inspector Maxi 900v • Probe Head: RENISHAW PH10M • Probe: RENISHAW TP2 + Ø5mm and Ø2mm Stylus • Measurement force: radial: 7 axial: 40 g • Laboratory temperature: 20 °C ± 1 °C • Measurement uncertainty (3σ): ± 0.006 mm • Unit: millimetre Stylus length = 370 mm Comment: The length of the stylus introduce an important error or uncertainty measurement

  4. Measurement problematic The length of the girder= 2000 mm Maximum CMM length moving = 1600 mm Comment: Blocks to support girder are outside the table.

  5. Cylindricity on gage cylinders Cylindricity Ø120 = 0.0096 mm Cylindricity Ø27 = 0.0016 mm Cylindricity Ø99 = 0.0116 mm

  6. Reference system Comment: the quality of the reference system is given by the geometry (common zone plan or line ) and the flatness of the surface. Z+ Y+ X+ LineY • Primary Z axis is the normal of the plane A: Common area of upper planes at each extremity, • Y axis is the intersection between plane A and plane B: B is the common area of lateral planes, • The origin is defined by the intersection of Y with the plane C: C is a part of the vertical plane at one extremity.

  7. Reference measurement conditions First measuring area of plane A Comment: It is very difficult to probe the reference surface because of the accessibility.

  8. Reference measurement conditions Second measuring area of plane A Comment: the plane A is the common zone built with the first and second area.

  9. Reference measurement conditions The common measuring area of plane B Comment: the common area is not exactly which was required.

  10. Reference measurement conditions Comment: it was impossible to completely measure the plane C. measuring area of plane C

  11. Measurement of the sagunder load

  12. Straightness of the axis Comment: the straightness considers all the cylinders except the centre of the Ø27 circle (beam tube).

  13. Positioning of circles R49.5,R60 and R13.5 Comment: The misalignment is more critical along Z axis.

  14. Location Ø0.01 mmof Circles R49.5,R60 and R13.5 Factor 10 Comment: LOCA = 2√(ΔX2+ΔZ2)

  15. Fiducialisation • The CMM size will not allow to measure the girder/cradles assembly during one step (the Epucret girder must be loaded while Boostec girders didn’t need)  it is necessary to fiducialise the assembly in 3 steps • Principle of the fiducialisation in 3 steps: fiducialisation of the loaded girder (already done), fiducialisation of the 2 cradles (already done), geometrical linking of the unloaded girder with its cradles by measurements at each extremities of temporary fiducials.

  16. Fiducialisation • 10 fixed fiducials (like for TM0) and 16 temporary points (removable hot glue). • Points on mean axis: • (according to metrology results)

  17. Conclusions • CMM volume is not large enough •  Fiducialisation in several steps •  External control • Machining out of tolerances •  Machining again? •  Adjustment by shimming? • Next steps •  Proposal of a schedule

  18. Proposal of external CMMs • When the assembly DB02E/cradles will be completed and fiducialised, we might consider to ask an external firm to measure it in one step, for example in France: • CETIM Senlis • CMM LEITZ 2400x 1200x 1000 mm • Accuracy :± 1.6µm + L/400 (have to be check) • BEA METROLOGIE Bordeaux • CMM HEXAGON 3000 x 1200 x 1000 mm • Accuracy :± 2.5µm + L/333 • SAPHIR PSMC Ain • CMM ZEISS MMZ2000x1200 x900 mm • Accuracy :± 2.7µm + L/300 • AXIS Valence • CMM Contura G2 ZEISS 2100 x 1200 x 800 mm • Accuracy :± 2.8 µm+L/300

  19. Proposal of a schedule • DB02E : EPUCRET GIRDER DB TYPE-1 for the LAB • DB01E : EPUCRET GIRDER DB TYPE-4 for the LAB • Etat des lieux : • Les V-supports de la poutre DB02E sont usinés (AP) • La poutre DB02E est fiducialisée (Sylvain Griffet et Dominique Pugnat) • Les berceaux (les 4) sont fiducialisés (Sylvain, Lillian Remandet) • Les pièces mécaniques des points d’articulations seront bientôt disponibles (Nicolas Chritin) • Ce qu’il reste à faire pour la poutre DB021E, dans l’ordre : • Plan d’assemblage de DB01E avec ses V-supports et les tolérances associées (Dmitry Gudkov) • Assemblage des V-supports sur DB01E (Philippe de Souza) • Usinage final des V-supports (AP) • Collage des fiducielles sur la poutre (Sylvain) • Mesures en métrologie, poutre chargée (Dominique)

  20. Proposal of a schedule • Ce qu’il reste à faire pour chacune des poutres, dans l’ordre : • Présenter le rapport de métrologie de chaque poutre en réunion CLIC module (Dominique et Sylvain) • Accord pour assemblage (CMWG), Sinon usinage des V ? Réglage ? • Préparation de la visserie (SU ou Philippe?) • Assemblage de deux berceaux par poutre et contrôle en temps réel (Philippe, Sylvain) • Mesure en métrologie des 2 assemblages poutre/berceaux en 2 fois (Dominique) • Sous-traitance de la mesure de l’assemblage poutre DB02E/berceaux dans une CMM plus grande (à définir?) • Transport au 169 pour installation (Nick Gazis?) • Contrôle des points d’articulation (au bras Romer) et assemblage sur berceaux (Sylvain, Philippe) • Plan d’implantation (Dmitri?), implantation (Sylvain), visserie (SU ou Philippe), perçage (Philippe ), réglage des tables (Sylvain), installation poutre (Philippe) • Contrôle des points d’articulation (Sylvain)

  21. Result flatness for plane A Supplementary slide

  22. Result flatness for plane B Supplementary slide

  23. Result flatness for plane C Supplementary slide

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