LUSI DCO XRay Focusing Lens System Final Design Review

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LUSI DCOX-Ray Focusing Lens System Final
Design Review

• Marc Campell
• Don Arnett
• June 25, 2009

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Agenda

• 1000 - 1030 Science Objectives and Requirements
• 1030 - 1130 X-ray Focusing Lens System Design
• 1130 - 1200 Questions Report Writing

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Goal of FDR

• Approval of the XFLS final design
• Approval to start fabrication
• Approval to place procurements
• Procurement of Be Lens has been initiated
• Long lead, foreign Vendor

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Agenda

• Status
• Key Features
• Positioning Requirements
• Final design and analyses
• Prototype test plans
• Comparison of XFLS IPM
• Analysis results
• Safety
• Cost schedule
• Identified problem areas/open issues
• Summary

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Status Overview

• XFLS PDR was passed based on similarity to
  Intensity Position Monitors
• IPM PDR passed on 1/09/09
• This review will also rely on work performed from
  the IPM FDR held on 4/17/09
• Relevant comments from the IPM PDR FDR will be
  addressed

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XFLS Key Features

• Focusing Lens concept based on proven design from
  Aachen University (Dr. B. Lengeler)
• Adapted to SLAC chamber design
• Commonality with IPM to reduce cost
• Extensive use of commercial hardware
• Aachen Design modified
• 3 sets of lenses and
• allow for Lens Pack removal with minor
  disassembly

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XFLS Key Features

• 2 axis actuator assembly
• Stem Assembly
• Be Lens Pack Holder
• IPM chamber
• (front face not shown)
• 6 degree of freedom support stand

X Stage
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XFLS Key Features

• 650 mm Z stage added for XPP and XCS

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Key Features (cont)

• Lens Pack Holder Assembly
• Has integral alignment features for the lenses
• Holds 3 Lens Pack Assemblies
• Each Lens Pack Assembly holds 12 Lenses

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Positioning Requirements

• Centers of all Lenses in a Lens Pack Assembly
  shall be co-axial within 10 µm.
• Four operating positions corresponding to the 3
  Lens Pack centers and the beam stay clear
  position.
• Lens Pack Assembly in the IN position shall be
  centered (X and Y) on the X-ray beam axis within
  the limits of Table I.
• The pitch and yaw of the lens must be less than
  0.1 relative to the LCLS coordinate system.
• There is not a roll requirement.
• Stay clear is .50 from beam centerline.

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Table I Positioning Requirements
Spec change in process for XPP and XCS only
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Cycle Life Requirements

• Actuators will be cycled once daily, 365 days a
  year for 10 years.
• X, Y Z cycles 3,650 at 72 /-5 F and 10-7
  Torr pressure.
• A cycle in X is 2.5 mm at positions IN 1, IN 2
  or IN 3.
• A cycle in Y is the following OUT position gt IN
  1 pausegt IN 2 pausegt IN 3 pause gt OUT position.
  (0 65 mm travel)
• A cycle in Z is 200 mm .

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Final Design

• XFLS design is identical to IPM except for the
  end effector on the shaft and it does not have
  the single axis actuator.

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XFLS Drawing Tree
Position Monitor Released Part
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Position Monitor Released Part
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Position Monitor Released Part
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(No Transcript)
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Lens Pack Assy Design

• Lens is a brass coin with either a Beryllium
  parabolic lens feature (active) or a hole in
  center (dummy).
• Purchased part
• Lens Pack Assy (LPA) holds 12 Lenses
• Retaining rods hold lenses for handling, but do
  not clamp parts together.

Shoulder feature Tab for handling
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Lens Pack Holder Design

• Lens Pack Holder holds 3 Lens Pack Assemblies
• Each Lens Pack Assembly holds 12 Lenses with
  different quantity of active or dummy lenses
• Allows change in X-ray spot size without breaking
  vacuum
• Lens Pack Holders V grooves
• Align the centers of the 12 coins relative to
  each other
• Establish pitch yaw of LPA via true position
  tolerance of V groove features relative to each
  other
• Tolerances can be met with CNC machining

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Lens Pack Holder Design (cont)

• Lens Pack Holder spring features (Inconel)
• Maintains LPA position in X and Z
• Allows for removal of LPA through X-face flange
• Provides repeatable positioning by preloading
  against V and front face.

Beam direction
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Stem Assembly Design

• Lens Pack Holder is bolted and pinned to base of
  stem
• Bellows allows X Y motion of stem

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Lens Pack Assembly Alignment

• Foci of the parabolas in the Be Lenses must be
  coaxial within 0.010 mm
• Not practical to measure this in a stack of
  lenses, however
• Parabolas are stamped into Be disc using tooling
  that references the OD of the coin
• Tolerance on OD of coin is approximately 0.002
  mm
• So referencing the OD of the coin to control the
  foci of the parabolas is valid
• The location of the focal point of each Lens Pack
  Assembly will be determined by in-beam scan and
  recorded.
• Pitch and yaw are corrected by adjusting the
  entire device with the support stand.
• Pitch, yaw and in beam scans repeated for each Z
  position required.

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Actuator Design

• Parker Daedal stage with IMS motor/controller
  used for Y stage
• stage repeatability spec is 1.3 µm
• Acceptance data from first IPM unit received had
  bidirectional repeatability of 0.2 µm on empty
  stage!
• IMS linear actuator and precision stages used for
  X axis

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XFLS Test Plan

• Fabricate all Lens Pack Holder Assembly
  components including dummy Lenses
• Demonstrate the following
• Manufacturing tolerances can be held
• Verify V groove positional tolerances
• Repeatability of LPA positioning after insertion
  retractions
• Spring forces required to position lenses
• Design of extraction tool if required

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XFLS Test Plan (cont)

• Mount Lens Pack Holder onto IPM first article
• Verify operation clearances in chamber
• Verify X Y stage repeatability

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Comparison with IPM

• IPM
• Mass 172 lbs
• 1 single 1 dual axis actuator assy
• Diode Electronics Module

• XFLS
• Mass 123 lbs
• 1 dual axis actuator assy

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Actuator Assy Comparison

• IPM
• End mass 0.7 lb
• Dual axis actuator assy
• Diode Electronics Module

• XFLS
• End mass 0.55 lb
• Dual axis actuator assy

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Requirements Comparison
Measured with respect to the top of the device
support structure
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Requirements Comparison (cont)
Spec revision in process Z axis requirements
for XPP and XCS only.
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Analysis

• Finite element analysis was performed for the IPM
• Analysis is being updated for the revised
  geometry
• 50 lb mass reduction from top of the device will
  improve modal response and should reduce
  displacements
• Vibration data taken in Hutch 3 4 can be
  inputted and displacements calculated

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Finite Element Analysis
Meshed FEA Model
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FEA Modal Analysis Summary
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FEA Modal Analysis
Figure 1 50.5 Hz Z bending
Figure 2 82.7 Hz X Carriage
sliding
Figure 4 124 Hz Z Chamber Top Plate in Torsion
Figure 3 101 Hz X Bending
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Safety

• Beryllium Lenses are a purchased part.
• No Be fabrication at SLAC
• Handling of finished beryllium parts per SLAC
  safety policies.
• Remote control of actuators
• May require shielding of the stage assembly for
  personnel safety to block pinch points.
• Radiation concerns addressed at Instrument level

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Schedule

• FDR held early to accommodate July 09 CD-3
  milestone
• Design Status Review 9/22/09
• XPP Ready for Installation April 2011

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XFLS Cost Breakdown

• Projected hardware costs are below 94,500
  budgeted.

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XFLS Summary

• Open issues
• Rerun FEA analysis
• Perform Engineering testing

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XFLS Summary

• Design meets the Physics Requirements
• Significant cost savings realized leveraging off
  IPM design
• Design complete
• Detailing 90 complete
• Drawing package started
• Engineering testing waiting for parts
• Requision in Procurement
• XFLS design is ready to proceed with procurement
  fabrication.
• Review Committee should approve proceeding.