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Fabrication and Quality Control of the Frequency Tuner for the XFEL

Fabrication and Quality Control of the Frequency Tuner for the XFEL. Lutz Lilje DESY European Linear Collider Workshop ECFA LC2013. Thanks !. Several people contributed with support and measurments to the work presented here :

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Fabrication and Quality Control of the Frequency Tuner for the XFEL

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  1. Fabrication and Quality Control of the Frequency Tuner for the XFEL Lutz Lilje DESY European Linear Collider Workshop ECFA LC2013

  2. Thanks! Severalpeoplecontributedwithsupportandmeasurmentstotheworkpresentedhere: R. Paparella, A. Bosotti, C. Albrecht, K. Jensch, O. Keller, K Przygoda, M. Grecki, C. Müller andmanymore also withinthe S1 Global Test at KEK

  3. Performance Tuningrange Lorentz forcecompensation Operation in FLASH Stepstowardsindustrialisation Mechanics Motor drive Piezosystem Currentstatus Disclaimer: Nodetails on Piezoamplifierormotordriver electronic givenhere Developmentswell on-track by LLRF WP andDESY groups MSK and MCS Outlineofthetalk

  4. Design by M. Maurier and P. Leconte based of the MACSE tuner design (CEA Saclay) DLarms DLcavity DLscrew Tuner Scheme • Current design in useat FLASH • Original design by CEA • Fast piezodetuningintroducedby DESY

  5. Piezo System Mechanics Drive Unit Tuner Parts: Overview

  6. Mechanicaltuner: Performance demonstrations • Tests ofmotorwithgearbox • Tuning rangetest • Test at S1 Global showsmorethan 400 kHz tuningrange • DESY testsmorethan 600 kHz • Expectedfromcavitiesis ~200 kHz • Hysteresis islow • Endurancetestsunderoperatingconditions (cold in vacuum) • More than 20 Million motorstepscorrespondingto 20 yearsofoperation • Motors survivedeventhe Isolation Vacuumcrashtest • Courtesyof KEK

  7. Piezosystemtest • Staticdetuning ~ 1 kHz • Demonstration of Lorentz forcedetuningcompensation • 35 MV/m compensated • Endurancetesting • Noproblemsexpected • Even after exposureto Helium atmosphere • Radiation exposurenoproblem • Permanent operation in FLASH since 1-2 years • Not yetfullyevaluatedin termsofendurancetesting

  8. S1 Global resultsofPiezotuner • Courtesyof KEK

  9. Lorentz Force Detunings in Module 6 Rocco Paparella INFN Lutz Lilje DESY -MPY- 2007

  10. TTF Module 6: Compensated Detuning per Cavity Rocco Paparella INFN Lutz Lilje DESY -MPY- 2007

  11. Piezo Voltages within margin maximum PI piezo voltage of 120 V at room temperature Could also use bipolar operation, but not needed Voltage on Piezo Needed for Compensation

  12. Mechanics Drive unit Piezosystem StepstowardsIndustrialisation

  13. Mechanicssuppliedby CEA • Adaptedtolocalsupplier in France Costreduction Materialquality • Steelwithlowpermeabilityneeded Therefore • Prototypeswithcompaniesexperienced in massproductionofprecisionmachinedpieces (for Airbus etc.) Conclusions • Severalsimplifications on thedetaileddrawings • Relaxed tolerancestoreducecost for precisionmachine time • Goodbasis for a successfulcall for tender Challenges for industrialisation: Mechanics

  14. Contractawardedto Astro- und Feinwerktechnik, Berlin Minor adaptionofdrawings After initialproblemswith material smooth production Quality control Agreement on ‚essential‘ measures Pre-seriescompletelycross-checkedat DESY Piezofixtureincoming check atPiezocompany QC protocolsdeliveredinto DESY EDMS systembycompany Industrial fabricationofmechanics

  15. Challenges for industrialisation: Motor and gear box • Basic idea from CEA: Step motor and harmonic drive • Initial tests failed due to insufficient coating • Lubrication under cold vacuum conditions tricky • DESY in-house development on coatings • Parts purchased via different sources • Integration/Assembly at DESY • Second motor supplier came into play later than expected • Cold testing possible at vendor • Therefore: • Training for at least two companies to deliver complete and tested drive units: • Motor, gear box, thread with nut • Test temperature liquid nitrogen, units under load • Use prototyping phase • Conclusion • Both vendors were capable to fulfill XFEL requirements • E.g. Life-Time

  16. ContractawardedtoHarmonic Drive, Limburg Minor adaptionofdrawings Quality control Agreement on few ‚essential‘ mechanicalmeasures Roomtemperatureandat liquid N2 temperaturetests Recordcurrentwhen Beginningofmovement Loss ofsteps Total numberofsteps QC protocolsdeliveredinto DESY EDMS systembycompany Industrial fabricationofdriveunit

  17. DESY development with several iterations • Guaranteeing sufficient pre-load for piezos • Avoid loose piezos under all operation conditions • Change of pre-tuning of cavities Assembly ‘hand-crafted’ at DESY No burn-in tests • One special case of failure at initial operation suspected • Not fully conclusive data Therefore: • Require companies to • Further improve radiation resistance (ETFE cabling) • Respect vacuum compatibility • assemble piezo systems • More than buying piezos only • Use experience of piezo companies for assembly • perform burn–in test • Room-temperature considered sufficient • Implementation in series production Challenges for indutrialisation:Piezosystem

  18. Contractawardedto PI, Karlsruhe PI Ceramics for Piezoelements Design improvedofdrawings Avoidlocalstresses on piezosbyoptimisingtheplatesused for pressingthepiezoelements Increasesthickness Definition ofsurfacequality Betterfixationofthewiring Industrial fabricationofPiezo System

  19. Quality control Burn-in test after assembly DC test 100 % of nominal voltage for 2 hours AC test Voltage:100% of nominal piezovoltage Pulse length:SinusoidalHalf Wave of 1000 Hz Rep rate: 100 Hz NumberofCycles: 1 Million After theteststhefollowingparametersshouldbemeasured Capacitance Stroke Leakagecurrentat nominal voltage QC protocolsdeliveredinto DESY EDMS systembycompany Industrial fabricationofPiezo System

  20. Test Procedures Automation during Module Assembly • Test both motor and piezo installation with an automated system • Proposal by INFN • Avoid polarity problems etc. • Successfully implemented

  21. Verification of current procedure Very detailed E.g. For training purposes Both Piezo and mechanical system Work of INFN with Module Assembly Team Assembly Procedures

  22. Mechanics: • Series fabrication ongoing. • Series piezo fixture delivery finished. Drive unit: • Documentation reports decided. • First units have FAT and been delivered to CEA and DESY. • Ramp up to series rate has been achieved. Piezo system: • Continuing tests of permanent FLASH setup. • Series production of fixtures ongoing. QC testing during module installation at Saclay (INFN contribution). • Series system completed (rack delivery). Fabrication of all tuner parts ongoing. Documentation in EDMS continues. Status of the System Components

  23. Piezosystems ~400 Normal tuners Tuner mechanics ~ 300 Motors ~80 Mirroredtuners Tuner mechanics ~ 50 Motors ~12 Numberofcomponents on 31stof July2013

  24. Thanks for yourattention!

  25. Backup Slides

  26. Tuner Pictures

  27. Cavity 3: Gradient 35 MV/m Rocco Paparella INFN Lutz Lilje DESY -MPY-

  28. Cavity 3: Phase Rocco Paparella INFN Lutz Lilje DESY -MPY-

  29. Cavity 3: Detuning Rocco Paparella INFN Lutz Lilje DESY -MPY-

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