Presentation is loading. Please wait.

Presentation is loading. Please wait.

T. Myers for J. Rathke - May 24, 2005 - HPSL Workshop - Slide # 1 of 17 SRF Design, Analysis, and Prototyping at AES Heavy Ion SRF Activites at Advanced.

Similar presentations


Presentation on theme: "T. Myers for J. Rathke - May 24, 2005 - HPSL Workshop - Slide # 1 of 17 SRF Design, Analysis, and Prototyping at AES Heavy Ion SRF Activites at Advanced."— Presentation transcript:

1 T. Myers for J. Rathke - May 24, HPSL Workshop - Slide # 1 of 17 SRF Design, Analysis, and Prototyping at AES Heavy Ion SRF Activites at Advanced Energy Systems, Inc. John W. Rathke, Chief Engineer Advanced Energy Systems, Inc. 27 Industrial Blvd, Unit E Medford, NY USA Phone: x110 Fax: HPSL Conference 24 May 2005

2 T. Myers for J. Rathke - May 24, HPSL Workshop - Slide # 2 of 17 SRF Design, Analysis, and Prototyping at AES

3 T. Myers for J. Rathke - May 24, HPSL Workshop - Slide # 3 of 17 SRF Design, Analysis, and Prototyping at AES AES Manufacturing Machine Tools HAAS VF-8/50 3 Axis CNC Mill, 64x40x30 HAAS VF-5/50 3 Axis CNC Mill, 50x26x26 Okuma 3 Axis CNC Mill, 40x20x20 HAAS SL-40 CNC Lathe, 40x 44 Length of turn Okuma CNC Lathe, 17.7 x 20 Length of turn HAAS TL-3 Hybrid Manual/CNC Lathe (2) Series 1 Bridgeport Mills - 30 Travel Harrison Gap Bed Lathe 16.5 x 40 Length of turn ( 24 w/ gap removed) Hardinge Tool Room Lathe 6 x 15 Length of turn Sheet Metal – Metal Forming LUNA Plate Bending Roller – 50 x 10 ga. Niagara Power Shear - 10 gage x 48 in. Whitey Metal Tool Sheet Metal Notcher 20 in. Hand Roller LVD Power Brake - ¾ Mild Steel x 48 in. Leaf Brake 16 Gage x 24 in. KR Wilson - 50 Ton Hydraulic Press Welding Equipment Hobart 400 Amp Arc Welder (2) Linde 300 Amp TIG Welders Cobramatic 300A MIG Welder Gas Cutting & Welding Outfit Cajon Orbital Arc Welder Argon Enclosure for Nb & Ti Welding Inspection Equipment Mitutoyo BRT-M507 Coordinate Measuring Machine – 20 x 28 x 16 Optical comparator Metrology Equipment (3) Brunson Optical Transit Squares (2) Wild Precision Optical Levels (2) Wild T-2 Theodolites (2) Taylor-Hobson Line Scopes (2) Talyvel Electronic Levels (3) Alignment Lasers Scope Stands, Scales, Targets, etc Chemical Treatment For pre-weld BCP of Nb components Millipore 35 lph Ultra-pure Water System w/ 350 liter storage Negative pressure room with 1200 CFM fume hood Class 10 laminar flow bench for drying and bagging. VF-8 VF-5 SL-40 CMM ~ 60% of main facility devoted to manufacturing ops. (8000 sq.ft.) Vacuum Test Equipment Varian Model 979 Mass Spectrometer Leak Detector with 1x Sensitivity Veeco Model MS-20T Mass Spectrometer Leak Detector with 1x10 -9 Sensitivity Turbomolecular pumping station Chemistry

4 T. Myers for J. Rathke - May 24, HPSL Workshop - Slide # 4 of 17 SRF Design, Analysis, and Prototyping at AES RF TEST LAB TECH LAB NC MACHINE SHOP CHEM LAB QC LAB MACHINE SHOP EB WELDER (Early 2006) OFFICES SHIPPING & RECEIVING WELD SHOP OFFICES RF TEST (FUTURE) LAB AES Facility Medford, NY N Sept 1998 – 7,800 ft 2 Nov 2003 – 11,500 ft 2 Summer 2005 (Plan) – 17,000 ft 2

5 T. Myers for J. Rathke - May 24, HPSL Workshop - Slide # 5 of 17 SRF Design, Analysis, and Prototyping at AES At AES Design Development is Continuous Iterative Process l Focus is to reach a mode of integration between disciplines that enables a seemless and constant exchange between physics and engineering –RF Layout –Design Engineering –Overall System Engineering l Initial AES activites in heavy ions stemmed from interactions with ANL staff on proton machines like APT and ATW. –Manufacturing planning and detailed costing.

6 T. Myers for J. Rathke - May 24, HPSL Workshop - Slide # 6 of 17 SRF Design, Analysis, and Prototyping at AES Heavy Ion SRF Prototyping at AES l Prototyping work for RIA/ATLAS has been ongoing at AES since 2000 l Prototyping is more than fabricating first-of-a-kind hardware. It is a process of design development, engineering analysis, manufacturing producibility analysis, and fabrication resulting in a robust Program Plan, Schedule, and Cost Estimate l Collaborating with ANL, AES worked to develop fabrication approaches for the different classes of cavities –Develop assembly sequence and detail part definition –Develop manufacturing flow plans and schedules –Develop cost estimates and facilities requirements l Five Cavities of four different types were then Prototyped –Quarter Wave Resonator –Half Wave Resonator –Double Spoke Resonator –Two Triple Spoke Resonators at =.50 and =.62

7 T. Myers for J. Rathke - May 24, HPSL Workshop - Slide # 7 of 17 SRF Design, Analysis, and Prototyping at AES The Prototyping Process at AES l Cavity Prototyping – General Flow –From ANL/AES Manufacturing studies detailed designs were developed at ANL –Designs (RF Definition with mechanical layouts) transferred to AES –AES performed the forming work and most machining of the niobium parts –Welding done by ANL at Sciaky in Chicago –Final Integration and Test at ANL l For the First Cavity, the Double Spoke Resonator, AES worked from AutoCAD layouts done at ANL l For the Final Cavities, the two Triple Spoke Resonators, AES imported Solid Models coming directly out of ANLs Microwave Studio and Pro/ENGINEER –Parts were fabricated with complex shapes that could not be dimensioned in the traditional sense of an engineering drawing –Paperless manufacturing l The QWR and HWR used a mixed technique in the transition l Engineering Analysis of the cavities also matured during this sequence –Concurrent Design and Analysis were utilizing the same models for rapid design evaluation during Prototype fabrication –The Triple Spoke stiffener scheme was developed concurrently with fabrication

8 T. Myers for J. Rathke - May 24, HPSL Workshop - Slide # 8 of 17 SRF Design, Analysis, and Prototyping at AES The Triple Spoke Example – Design, Analysis, Fabrication Flow STEP File Solid Model of RF Space ANL – MWS Model Skin the Model (ANL & AES in Pro/E) Resulting Pro/E Assembly with Detail Parts Design & Manufacturing Engineering Analysis ANSYS Model of Structure (w/ He Vessel) and RF Space

9 T. Myers for J. Rathke - May 24, HPSL Workshop - Slide # 9 of 17 SRF Design, Analysis, and Prototyping at AES Analysis Example - Triple Spoke Model Stiffener Analysis l Design issue: Spoke resonators exhibit frequency shift due to variations in helium pressure l Analysis performed under the guidance of K. Shepard to attempt to null out that effect In ANSYS, a structural model of the cavity/helium vessel structure and an RF model of the resonator RF Space were built. These models share common surfaces at the interface and deformations from the structural analysis are mapped onto the RF model where the f is calculated A stiffener geometry was developed that reversed the sign of the f and allowed fine tuning by machining the stiffeners after fabrication l A second series of analyses is shown that examines the effect of a fast piezoelectric tuner l Performance was verified during cavity testing 16 radial stiffeners psi in helium space

10 T. Myers for J. Rathke - May 24, HPSL Workshop - Slide # 10 of 17 SRF Design, Analysis, and Prototyping at AES Stiffener Analysis Result – Tune by Machining f with no stiffeners = kHz l 16 Radial Stiffeners added – f = kHz with full stiffeners (right) – f = kHz with machined stiffeners (left) –Total tuning range of kHz Radial Displacements inches Load = 14.7 psi in helium space Properties evaluated at RT Radial Displacements inches Cavity with Full Stiffeners.075 in..50 in. Cavity with Machined Stiffeners R.12 in.

11 T. Myers for J. Rathke - May 24, HPSL Workshop - Slide # 11 of 17 SRF Design, Analysis, and Prototyping at AES Fast Tuner Study Analysis to determine the effect of 20 m actuation of piezoelectric tuner Analysis Result f = +120 Hz Verified in Cavity Test Radial Displacements inches Cavity Properties evaluated at RT 20 micron actuation results in 14.9 lbs of load in the actuator Radial Displacements inches Helium vessel Distribution of Radial Displacements (in.) Cavity side e-3 Helium vessel side e-3 Tuner Location – Chosen by ANL to Maximize Tuner Effect

12 T. Myers for J. Rathke - May 24, HPSL Workshop - Slide # 12 of 17 SRF Design, Analysis, and Prototyping at AES The Fabrication Flow - Develop Detail Parts Full Pro/E Assembly ANL Center Spoke Assembly Exploded View of Detail Parts for Fabrication

13 T. Myers for J. Rathke - May 24, HPSL Workshop - Slide # 13 of 17 SRF Design, Analysis, and Prototyping at AES Multi-Piece Multifunction Tools Directly from MWS Geometry Geometry Direct from MWS Into Pro/E Tooling Models and Direct to NC Machines (STEP & IGES) Spoke Half Forming/Machining Tools Beam Tube Saddle Forming/ Machining Tool Spoke Saddle Forming/ Machining Tool

14 T. Myers for J. Rathke - May 24, HPSL Workshop - Slide # 14 of 17 SRF Design, Analysis, and Prototyping at AES ANL RIA Triple Spoke Fabrication at AES – Spokes & Tank

15 T. Myers for J. Rathke - May 24, HPSL Workshop - Slide # 15 of 17 SRF Design, Analysis, and Prototyping at AES ANL RIA Triple Spoke Fab. at AES – End Walls & Assembly M/C End Wall Forming Tools As-Formed End Walls Ready for Beam Tube Weld Trim Cavity Ends Prior to Tuning Ready for Tuning

16 T. Myers for J. Rathke - May 24, HPSL Workshop - Slide # 16 of 17 SRF Design, Analysis, and Prototyping at AES ANL RIA =.50 Triple Spoke Tuning at AES 1 st Bead Pull 4 th (Final) Bead Pull f 0 = MHz f 0 = MHz Target Frequency f 0 = MHz Field Balance +/- 5% Performing Bead Pull In Bead Pull Fixture Machining End Wall Flange for Tuning

17 T. Myers for J. Rathke - May 24, HPSL Workshop - Slide # 17 of 17 SRF Design, Analysis, and Prototyping at AES Summary & Conclusions l ANL / AES have collaborated to produce five first-of-a-kind prototype cavities for RIA / ATLAS l This collaboration spanned the full design development horizon from Project Planning & Cost Estimating through Manufacturing & Producibility through Design & Analysis and finally through Fabrication l Under the leadership of ANL, the collaboration utilized the strengths of all organizations in a well integrated, concurrent development environment l The Triple Spoke example highlighted here is a blueprint for collaborations of this type in the future


Download ppt "T. Myers for J. Rathke - May 24, 2005 - HPSL Workshop - Slide # 1 of 17 SRF Design, Analysis, and Prototyping at AES Heavy Ion SRF Activites at Advanced."

Similar presentations


Ads by Google