Summary of the past and future work with the HEIG-VD on the wire-scanner design BI seminar 26 September 2014 J.Emery for the BWS team

Content System overview Design guidelines Motivation for collaboration Institutes presentation and contributions Summary BI seminar BWS collaboration with the HEIG-VD

BWS System design 1/2 Moteur frein bloquant résolveur Chambre interne Axe de rotation Fourche Fil Disque lithographié Fibre optique et focalisateur BI seminar BWS collaboration with the HEIG-VD ‘BWS design review 2013’ Indico or SVN ‘Design and construction of a new actuator for the LHC Wire Scanner’, PhD thesis, Mohamed Koujili SVNIndicoSVN ‘Vacuum Actuator and Controller Design for a Fast Wire Scanner’, J. Emery, B. Dehning, J.F. Herranz, M. Koujili, J.L. Sirvent, BIW2012BIW2012

Secondary particles shower acquisition Scanner control, monitoring and supplies “Intelligent drive” Acquisition and supervision CPUCPU CPUCPU TIMINGTIMING TIMINGTIMING BST receiver BWS System design 2/2 Fast integration secondary shower SFP Ethernet SFP Optical link Long range resolver interface 3-phases PWM Magnetic stopper External temperature and vibration Wire resistivity & Strain gauge HVCTRLHVCTRL HVCTRLHVCTRL Optical encoder interface BI seminar BWS collaboration with the HEIG-VD ‘Beam Scanner Control, Monitoring and Supplies part’, engineering specification, CERN EDMS EDMS

Design guidelines Operational system failures analysis Mechanical, Electrical and acquisition chain Failures senarios and mitigation 1) Minimisation of complexity 2) Separate critical and non-critical functions 3) Early failure detection Goals: Performance, Maintainability & availability, Usability BI seminar BWS collaboration with the HEIG-VD

Operational system failures for all scanner types since 2009 Multiplexers Step motor control Power amplifier behind the VME Cabling / Electronic VME cards / crate Affected Component machineOccurrencesFailure sourceMitigationSystem under design Linear Power Amplifier All & lab16 (2 in 2012)Electrical glitch to unprotected outputs, Use of componant (PA50) on the limit of its specification Replacement of supplies Use of switch mode power supplies and filters MultiplexersLHC, PS3Mechanical relay failure in the tunnelReplacement of relays Use dedicated cables and control electronics Step motor controler PSB, LHC2Electronic board agingEnd of life electronics to be upgraded Avoid filter wheel by the use of high dynamic detector Motion control PS1VME bus access switch off VMEReplacement of the card Motion control in the power supply disconected from the VME CPU RIO 3SPS1Unexpected rebootReplacement of the card PA50A => For the future scanner, use switch mode power conversion validated BWS Power amplifier Transformer DC power storage units (Capacitors) ±32V DC power storage units (Capacitors) ±32V motor AOP 150m BI seminar BWS collaboration with the HEIG-VD

Failures scenarios Beam – wire and movement Failurescenariosconsequences today Possible causeExisting Safety procedure Today implementation future scannersFuture implementation (proposal) Wire melting And High beam losses Beam Intensity too high compared to nominal speed Exchange scanner and/or Exchange scanner New beam injection after the trigger of the scan. Before scan: Inhibit movement RT softwareX Nominal speed handle highest intensity Firmware through hardware link. Scanner speed setting too low compared to beam intensity Exchange scanner and/or Exchange scanner Tests, new beam injection after the trigger of the scan. xxBefore scan: Inhibit movement During scan? Firmware through hardware link. Return home? Fork movement don’t follow the expected profile Speed too lowWire melting And/or High beam losses Position Feedback stability lost. High mechanical friction, motor fatigue, power supply issue During scan: ‘Return home’. Risk of breaking wire + Forks Analog electronics Different cases implantable: -Finish movement if safe. -Stop and return home Firmware monitoring of feedback and safety action. Speed too highScanner can’t stop and hit the tank. Wire + fork Position Feedback stability lost. High mechanical friction, motor fatigue, power supply issue During scan: ‘Return home’. Risk of breaking wire + Forks Analog electronics If scanner can’t slow down: Only wire broken Firmware monitoring of feedback and safety action. Vibrations of tank/Shaft/fork /wire Values above limitsNo detectionAging, position feedback/motor issue xxChange of position profile / emergency stop Firmware CERN wire-scanner development review J.Emery

Motivations for external collaborations High technical competencies needed during the designs phase Large variety of subjects Limited resources due to operational duties High knowledge return expected for this type of collaboration. In depth knowledge and higher performance compared industrial solution BI seminar BWS collaboration with the HEIG-VD

Institute for Industrial Automation (IAI) Mechatronics, Control, Automation, Industrial electronics, Industrial Control Software, Signal and image processing, Industrial optics and vision Brainstorming in September 2011 to identify potential collaboration Study and simulation of the Optical Position Sensor => Was done by tech student, J. Sirvent, 2012, Thesis Optimisation of Position Control (& Implementation) => Is being done by tech student, Matteo Macchini, Study of the use of switch mode powering for the motor => Identified to be fulfil through Mandate collaborationThesis Mandate called ‘EMC study for the control of Wire Scanner ‘ ( ) Report release in July 2013 EDMS_ EDMS_ BI seminar BWS collaboration with the HEIG-VD

Mandate objectives Proof of concept: Use of a switch mode techniques for the wire scanner motor. a)Simulation of motor mouvement using switch mode driving system. b)Selection of a suitable output filter. c)Prototyping using DSP system. d)EMC measurements and comparison with linear system. BI seminar BWS collaboration with the HEIG-VD

Study of switch mode motor powering (Inverter) principle for the wire-scanner actuator Models development of - Power supply - Output filtering - Long cable to be used - Motor for high frequency - Simulation of the EMI Validation of the position feedback stability of such system Implementation of this system with their electronics EMI measurements and comparison with current implementation using linear drivers Our motor! BI seminar BWS collaboration with the HEIG-VD

Switch mode output filter principle Results: Reduction of ElectroMagnetic Interferences (EMI) Better compatibility with signal cables neaby this cable Shielded power cable 6mm2 BI seminar BWS collaboration with the HEIG-VD

Models for the SMPS simulation Switch mode Filter Cable Motor BI seminar BWS collaboration with the HEIG-VD

Study Outcome Principle validated with long cables by simulation and experience Position feedback is stable and correct dynamic Physical implementation on their bench with our motor finished Filtering reduces considerably the emitted interferences (see measure, using parallel cable as receiver) BI seminar BWS collaboration with the HEIG-VD

Institute for Industrial Automation (IAI) Future work On-going mandate preparation consulting during the design of the power part Power design of an inverter (600V, 50A) and additional functions foreseen. BI seminar BWS collaboration with the HEIG-VD

Reconfigurable & Embedded Digital Systems (REDS) Efficient Information Processing, Heterogeneous Device Support, Integrated Design of Embedded Systems Brainstorming in Sept to identify potential collaboration Resolver data processing in a FPGA => Bachelor thesis by Kevin Henzer, 2013, edms_ Ethernet interface with a System On Chip based FPGA => Bachelor thesis by Kamil Florek, 2014, edms_ edms_ edms_ BI seminar BWS collaboration with the HEIG-VD

Resolver data processing in a FPGA 1/2 BI seminar BWS collaboration with the HEIG-VD Fully differential Driver and receiver prototype (By Carlos Pereira) Use FPGA Starter kit & code of Kevin’s Bachelor

Resolver data processing in a FPGA 2/2 Study of different RDC methods (tracking, FFT, arctan) Simulation and implementation using DSP Builder (Simulink to FPGA) Validation using dedicated bench with the resolver and an Higg precision encoder BI seminar BWS collaboration with the HEIG-VD

Application for the Ethernet interface with a System On Chip based FPGA => Fast prototype for the first beam measurements example BI seminar BWS collaboration with the HEIG-VD 1Gbps Ethernet MatLab lib Position ctrl optimisation scripts See K. Florek presentation PWM inverter Resolver interface Wire interface PMT interface (slow) Magnetic blocker Power PWM + Resolver + wire on FMC Optical encoder interface on FMC

Institute for Energy and Electrical Systems Electrical network distribution, Electrical machines, Electro- mechanical system simulation and control, Power electronics and conversions Brainstorming in Sept to identify potential collaboration Motor selection check and new design => Bachelor thesis by Colin Grosjean, 2014, edms_ edms_ BI seminar BWS collaboration with the HEIG-VD

Motor and Break Design Initial motor performances not compatible with final inertia (3 times higher) BI seminar BWS collaboration with the HEIG-VD See C. Grosjean presentation Initial motorNew motor field lines simulationBreak

Scanner control, monitoring and supplies “Intelligent drive” Summary SFP Ethernet SFP Optical link Long range resolver interface 3-phases PWM Magnetic stopper External temperature and vibration Optical encoder interface Wire resistivity & Strain gauge BI seminar BWS collaboration with the HEIG-VD Bachelor K. Florek (2014) Mandate IAI ( ) Bachelor K. Henzer (2013) Bachelor C. Grosjean (2014) Proposal (2015) Proposal (2015) Power design