Midterm Review 28-29/05/2015 Iordan Doytchinov ESR3.1, WP3 1

ESR3.1, WP3 /  Contract start date: 3 rd March 2014  PACMAN subject: Ultra-precise quadrupole magnet assembly and testing. Integration of an alignment test-bed towards an industrial production  PhD title: Measurement uncertainty budget for future particle accelerators alignment bench  PhD Institution: Cranfield University  Secondment: DMP Spain (3M) Iordan DOYTCHINOV, ESR3.1 PACMAN Mid-term review 28-29/05/2015 CERN SupervisorMichele Modena Academic supervisorsDr. Paul Comley, Prof. Paul SHORE Industry supervisorJorge Presa 2

Background / Test automation - 1 year Vehicle Dynamics/ Performance - 3 months Omron ltd Barcelona: Real-Time robot dynamics simulation (Master THESIS) UAV Performance Estimation /system Integration I come from here - Sofia - BULGARIA Beside Engineering… Iordan DOYTCHINOV, ESR3.1 PACMAN Mid-term review 28-29/05/2015 3

PhD thesis /  Title: Measurement uncertainty budget for future particle accelerators alignment bench  Start date:  Status: 1 st year critical (GO/NO-GO) review passed  Note: Precision engineering training done at the university. Iordan DOYTCHINOV, ESR3.1 PACMAN Mid-term review 28-29/05/2015 4

Project / Place in PACMAN Iordan DOYTCHINOV, ESR3.1 PACMAN Mid-term review 28-29/05/2015  Ultra-precise quadrupole magnets assembly and testing  Uncertainty budget for PACMAN and thus: Work contributed to PhD hypothesis formulation but not selected as one. research plan reformulated to follow closely PhD hypothesis  Bench System Integration – evaluation of system requirements and bottleneck problems A)Defining its measurement capability. B) Development of calibration and error compensation procedures for the system. C) Proving if the concept can be scaled up for mass production. 5

Project / Objectives Iordan DOYTCHINOV, ESR3.1 PACMAN Mid-term review 28-29/05/ I) Define error sources contributing to the measurement uncertainty (current work) JCGM 100:2008 P.R. Guimarães Couto1 et all (2013) II) Allocate the level of measurement uncertainty for each critical error source III) Construction of final integrated system uncertainty budget. Prove or disprove if targeted measurement uncertainty is achievable: 7 µm (BPM axis) 11 µm (Magnet axis) Future work

Project/ BPM Iordan DOYTCHINOV, ESR3.1 PACMAN Mid-term review 28-29/05/ State of the art

Project/ Iordan DOYTCHINOV, ESR3.1 PACMAN Mid-term review 28-29/05/ Magnetic axis definition Wire axis non- contact definition within CMM Tactile datum measurement  No in-depth uncertainty analysis  No common terminology or method applied  Integrated uncertainty budget does not exist GAP OF KNOWLEDGE: Wire Sensor BPM axis definition Research Gap

Project / Method followed Iordan DOYTCHINOV, ESR3.1 PACMAN Mid-term review 28-29/05/2015 II) Literature review I)QFD analysis, CAD studies, communication with sub system owners (PACMAN students) - System integration, definition of error sources Measurement Process Uncertainty budget Change assumptions Task -Standards (GUM, ISO) -Error budgets on complex systems III) Experiments design - Evaluation of magnitude, sensitivity and correlation of uncertainty contributors in 4x work packages Experiments package 1 ( ) Magnetic axis measurement package BPM electric axis measurement package Wire axis location measurement package CMM task specific measurement uncertainty evaluation package 9

Project / Tasks description Iordan DOYTCHINOV, ESR3.1 PACMAN Mid-term review 28-29/05/2015 Schedule 10 1st Year review 2 nd year review 1st Objective 2nd Objective 9 months GO/ NO-GO 30 th of April DMP secondment – Magnetic axis definition uncertainty budget evaluation Zero datum uncertainty budget evaluation Electric axis definition uncertainty budget evaluation Non-contact uncertainty budget evaluation nd Year GO/NO-GO PACMAN integrated system U evaluation package Thesis preparation

Results Iordan DOYTCHINOV, ESR3.1 PACMAN Mid-term review 28-29/05/2015 Assembly not trivial – errors correlate: Magnetic axis measurement to be included in the magnet assembly loop? Practical assembly studies of quadruple magnet investigating existing methods 11  Literature review on the subject  Assembly trials completed: Results:

Relationship Matrix Quality Function Deployment initial analysis done: Results Iordan DOYTCHINOV, ESR3.1 PACMAN Mid-term review 28-29/05/2015 Project / Metrology loop interference No access for non-contact sensor A)Re-design B)Change of strategy 12

Uncertainty analysis Results Iordan DOYTCHINOV, ESR3.1 PACMAN Mid-term review 28-29/05/2015  Quantify ΔT for current thermal control state of art  How ΔT of magnet propagates to magnetic axis measurement? Udt= ΔT x α x L? Magnetic axis measurement BPM electric axis measurement Wire axis location measurement Zero datum measurement (CMM) ΔTΔT Time T ΔTΔT dt 13

Training Iordan DOYTCHINOV, ESR3.1 PACMAN Mid-term review 28-29/05/2015  Secondment in DMP – Spain( ): “Analysis of error budget and uncertainties of robotic mechanisms for measuring the spine movement during transpedicular approach surgery”  Opportunity to practice kinematics mechanism error propagation budgeting  Opportunity to spent time in precision engineering company: Introduced to internal standards and procedures on metrology and manufacturing.  Precision engineering training in Cranfield University  1 week (11 principles of precision design) 1. Structure 2. Kinematic / Semi Kinematic Design 3. Abbe Principle 4. Direct Displacement Transducers 5. Metrology Frames 6. Bearings 7. Drives / Carriages 8. Thermal Effects 9. Servo-Drives and Control (CNC) 10. Error Budgeting 11. Error Compensation 14

Training / Iordan DOYTCHINOV, ESR3.1 PACMAN Mid-term review 28-29/05/2015  Training (at CERN) on metrology and alignment -3 day ISO GD&T course -2 day general metrology -1 week spent as apprentice in metrology laboratory  Training (at CERN) on CATIA software – 2 weeks  Training (at CERN) on ANSYS software – 1 week 15  “Teambuilding” development course (1day)  Presentation making development course (3days)  Language course – basic level French

Conferences & workshop:  Participation to EUSPEN 2014 Meeting on Thermal Issues  Participation and presenting in PACMAN workshop  CONTROL fair Stuttgart (discussed and shared PACMAN project with industry ) Outreach & Dissemination / Iordan DOYTCHINOV, ESR3.1 PACMAN Mid-term review 28-29/05/2015 Other:  CERN guides training 16 At CERN

Networking Opportunities / Iordan DOYTCHINOV, ESR3.1 PACMAN Mid-term review 28-29/05/2015  Visit at KOTEM technologies in Budapest  Organised a visit and presentations of KOTEM and SIGMETRIX tolerance analysis software companies at CERN  CONTROL fair Stuttgart  PACMAN workshop  Discussions and online meetings with PhD students from Brazilian Synchrotron Light Source working on similar project 17

Impact Iordan DOYTCHINOV, ESR3.1 PACMAN Mid-term review 28-29/05/2015  Contribution to DMP research project error and uncertainty analysis for medical purposes (DMP) 18 Personal  Dissolution my borders  Made me believe Professional  Contribution to system integration required for PACMAN project (CERN)  Contribution to state of art in uncertainty analysis in accelerator components pre-alignment (CERN)

Midterm Review 28-29/05/2015 Thank you for your attention “If you grasp the principles – myths fall & Ideas take-off” David Lentink (TUDELFT) TED Conference Amsterdam (“ برج خليفة ‎, "Khalifa Tower“) – Dubai 2010 Babylon tower by Tobias Verhaecht (1561 – 1631) 19