1. Team: Wolfgang Burkert, Haimo Jöhri, Uwe Barth Mechanical precision and vibration behavior of mechanical supports Johan Wickström GFA-ATK

2. 27.01.09 Johan.Wickström GFA-ATK, Paul Scherrer Institute Switzerland 27.01.09 2 BRIDGE AARE PSI XFEL LAYOUT

3. 27.01.09 Johan.Wickström GFA-ATK, Paul Scherrer Institute Switzerland 27.01.09 3 GIRDER JACKS FLOOR SUPPORTS COMPONETS SETUP of Mechanical structures 250 MeV

4. 27.01.09 Johan.Wickström GFA-ATK, Paul Scherrer Institute Switzerland 27.01.09 4 GIRDER JACKS FLOOR SUPPORTS COMPONETS floor unlevel +-10mm pre positioning +-1mm machined precision longitudinal 0.01mm/1m vertical +-0.1mm precision from alignment driving wedge or distance block 0.01mm stability of component structure SETUP of Mechanical structures General

5. 27.01.09 Johan.Wickström GFA-ATK, Paul Scherrer Institute Switzerland 27.01.09 5 4700mm 820mm/ 920mm 1200mm 570mm 820mm mass 3800kg /4400kg Girder Dimension 250 MeV

6. 27.01.09 Johan.Wickström GFA-ATK, Paul Scherrer Institute Switzerland 27.01.09 6 W.Burkert

7. 27.01.09 Johan.Wickström GFA-ATK, Paul Scherrer Institute Switzerland 27.01.09 7 Girder Dimension Fabrication

8. 27.01.09 Johan.Wickström GFA-ATK, Paul Scherrer Institute Switzerland 27.01.09 8 Spherical contact head Vertical adjustment Horizontal adjustment 1 turn = 0.3mm Standard driving wedge Compact and massive design Fixation of movement possible Girder Jack J.Haimo

9. 27.01.09 Johan.Wickström GFA-ATK, Paul Scherrer Institute Switzerland 27.01.09 9 Reference area Clamping element Distance block or Driving wedge Screw for lifting J.Haimo Support for Components

10. 27.01.09 Johan.Wickström GFA-ATK, Paul Scherrer Institute Switzerland 27.01.09 10 Height: 20mm +/- 0.5mm 1 turn = 0.1mm adjustment of height Scale : 0.1mm / mark Scale : 0.01mm / mark Footprint : 38 x 65mm J.Haimo Driving Wedge

11. 27.01.09 Johan.Wickström GFA-ATK, Paul Scherrer Institute Switzerland 27.01.09 11 Lifting Spreader 7.5 tons

12. 27.01.09 Johan.Wickström GFA-ATK, Paul Scherrer Institute Switzerland 27.01.09 12 Why mineral Cast ? –high damping properties expected, non homogenous material –relatively high mass vs. load change good for many setups –cost effective in mass production (no high temperature) about 3 weeks delivery with existing mould one wooden mould gives ~10 girders one steel mould gives +100 girders –surfaces can be grinded >> precision 0.01mm/1m length –no local stresses introduces by machining WEAK Points –fragile edges - corners –minimal wall thickens +80mm –mould costs during prototyping –unknown factors? design Today 250 MeV – PSI XFEL

13. 27.01.09 Johan.Wickström GFA-ATK, Paul Scherrer Institute Switzerland 27.01.09 13 –estimate eigenfrequency and deformations of girder –3 feet or 4 feet solution considered –several feet locations considered –target eigenfrequency above 40 Hz –sacking deformation of low relevance since machining done on support points –sacking from 10-20μm Eigenfrequency analysis of mechanical supports

14. 27.01.09 Johan.Wickström GFA-ATK, Paul Scherrer Institute Switzerland 27.01.09 14 ModusFrequenz [Hz] 158 2102 3112 4140 5171 6191 3 Feet downstream + Load Eigenfrequency analysis of mechanical supports

15. 27.01.09 Johan.Wickström GFA-ATK, Paul Scherrer Institute Switzerland 27.01.09 15 4 Feet downstream + LOAD Optimal Feet Distribution First mode 128 Hz ModusFrequenz [Hz] 1102 2117 3135 4155 5190 6 Eigenfrequency analysis of mechanical supports

16. 27.01.09 Johan.Wickström GFA-ATK, Paul Scherrer Institute Switzerland 27.01.09 16 analysis Summary –Deformation not important can be machined out –Clearly 4 feet more stable and symmetric behavior –Component support also need optimizing –Feet location important –Lifting feet dose only bring advantage if beam lower down –Real measurements will prove how the complete setup will perform Eigenfrequency analysis of mechanical supports

17. 27.01.09 Johan.Wickström GFA-ATK, Paul Scherrer Institute Switzerland 27.01.09 17 Development of mechanical supports is well underway, during the spring we will have a confirmation of the mineral cast material for the functionality as a girder. As well as the functionality of the jacks, supports and the alignment wedges. FEM eigenfrequency calculations should be done for the complete chain of mechanical supports + possible confirmation by measurement - magnets, RF structures, diagnostics, undulators, laser transfer, etc For PSI-XFEL – check beam distance to supports, beam height, floor trench for girder, 3 – 4 feet, feet location handling and transport questions - time and tooling, tunnel size Further comparison to other potential material like SiC should be carried out, possibly in scaled down size Thanks to All the great colleges that work together for this interesting and challenging development! Summary