results of short module and qualification strategy
DESCRIPTION
Results of short module and qualification strategy. PIMS production meeting 26-27 February 2013 Rolf Wegner. Production qualification, April 2012. Status of machining qualification, 19.04.2012:. Review of steps towards qualification. Meeting at CERN in March 2012: - PowerPoint PPT PresentationTRANSCRIPT
Results of short module and qualification strategy
PIMS production meeting 26-27 February 2013
Rolf Wegner
PIMS production meeting 26-27 February 2013 Rolf Wegner 2
Production qualification, April 2012Status of machining qualification, 19.04.2012:
Step std + central disc
end disc(cooling ch.)
ring by milling
ring by turning
WG-ring
1st rough (+2mm)
ok(10.01.2012)
ok(10.01.2012)
ok(10.01.2012)
ok(19.04.2012)
brazing test => horizontal or vertical brazing ?
2nd rough (+1mm)
ok(30.03.2012)
ok(30.03.2012)
Ring G_13-14:
serious non-conformities=> repair of EB-weld
Ring G_1-2: serious non-conformities=> machining tests
3rd rough(+0.2mm),
final
Full Quality Assurance Report+ check at CERN
Full Quality Assurance Report+ check at CERN
Full Quality Assurance Report+ check at CERN
Full Quality Assurance Report+ check at CERN
Full Quality Assurance Report+ check at CERN
26.02.2013
PIMS production meeting 26-27 February 2013 Rolf Wegner 3
Review of steps towards qualification
26.02.2013
•Meeting at CERN in March 2012:
* machining procedures optimised (=> clamping) [parts seen 5 to 10 times out of tolerance]
* specifications very tight; small performance degradation <=> accepting certain deviations from specifications (EDMS 1209460)
* recommendation: final machining on a lathe
•Meeting at NCBJ in April 2012:
* green light for rough machining of discs for series
* Quality Assurance Report form defined
•Mai 2012:
* new weld qualification with cosmetic pass + repair of weld for ring G_13-14
* preliminary metrology end disc M_1 => green light to finish end disc M_14 and disc M_6-7
•June 2012:
* brazing test finished
PIMS production meeting 26-27 February 2013 Rolf Wegner 4
Review of steps towards qualification
26.02.2013
•July 2012:
* QA report disc G_2-3 ok, end disc M_1 ok, shipment to CERN
* QA report disc M_6-7, re-machining of assembly ø524 requested
* QA report end disc M_14, agreed on adaptation of ring M_13-14 - side 14 for assembly ø524
•September 2012:
* welding of ring M_13-14 ok, defect on ring M_1-2 => sent for repair to Julich=> using ring G_13-14 as 2nd ring for short module
* brazing test evaluated at CERN (visual inspection, ultrasound & vacuum tests), very good result, => green light to produce waveguide ring cavity M
* disc G_2-3, end disc M_1 inspected at CERN => green light for finishing all discs cavity M
•November 2012:
* QA report ring M_13-14
PIMS production meeting 26-27 February 2013 Rolf Wegner 5
Review of steps towards qualification
26.02.2013
•December 2012:
* QA report re-machined ring G_13-14 => green light for finishing all rings cavity M
* end disc M_14, disc M_6-7, ring M_13-14 and ring G_13-14 arrived at CERN
•January 2013:
* QA report discs M_2-3, M_12-13
•February 2013:
* QA report discs M_4-5, M_10-11
PIMS production meeting 26-27 February 2013 Rolf Wegner 6
Quality Assurance Reports
26.02.2013
•=> "Disc G_2-3 - Analysis & Comparison CERN.xlsx"
* report form from NCBJ exactly as desired
* analysis to specifications
* analysis to acceptable dimensions
* comparison to CERN measurements
•metrology machine accuracy: ± 6 μm
=> comparison precision: ± 12 μm
=> specifications 500 mm ± 10 μm difficult to machine and difficult to measure !!!
results quite similar (a few small points to discuss tomorrow)
PIMS production meeting 26-27 February 2013 Rolf Wegner 7
Vacuum tests at CERN
26.02.2013
end discs M_1, M_14; disc G_2-3; ring M_13-14 all leak rate < 2*10-11 mbar*l/s
PIMS production meeting 26-27 February 2013 Rolf Wegner 8
Brazing test at NCBJ
26.02.2013
• good visual impression
• vacuum tight (leak rate <1*10^-10 mbar l/sec)
• good ultrasound analyse results
• Agostino: ”It is hard to do it better”
=> Green light for brazing of WG ring of 1st cavity (25.09.12)
PIMS production meeting 26-27 February 2013 Rolf Wegner 9
Machined parts, end discs M_1 and M_14
26.02.2013
element EDMS remarks slight deviations* serious deviations* where leak tight
cavity suited
end disc M_1
1243403 surf. roughness <0.8
Ø524: gap +16 μmcooling channels (wall >5.0mm)survey hole 1 8H7 8.37 mm but NCBJ and CERN metrology deviate ≤ 54 μm
none CERN yes yes,ready
end disc M_14
1253682 surf. roughness <0.8
scratches, craters⌾Ø518: +33 μmnose position: +10 μmØ524: gap -31 μm => adjacent ring opened by 30 μmcooling channels (wall >5.0mm)some holes too short (1.. 2 mm)
⌾Ø524: +74 μm CERN yes tbd,ready
* to acceptable dimensions
PIMS production meeting 26-27 February 2013 Rolf Wegner 10
Machined parts, disc M_6-7
26.02.2013
element EDMS remarks slight deviations* serious deviations* where leak tight
cavity suited
disc M_6-7
1253702 scratches, craters⌾Ø518: +43 μm / +16 μmØ524: gap -5 μm / 57 μm⌾Ø524: +20 μm / 26 μmØ538: +25 μm / + 23 μmnose length: -5 μm / +12 μmnose position: +19 μm / 35 μmcoupling slot symmetry & R15cooling channels (wall >5.0mm)
surf. roughness nose cone 1.0 to 2.8 μm side 7burrs on all cooling channels => to be re-machined
CERN
* to acceptable dimensions
PIMS production meeting 26-27 February 2013 Rolf Wegner 11
Machined parts, ring M_13-14
26.02.2013
element EDMS remarks slight deviations* serious deviations* where leak tight
cavity suited
ringM_13-14
1252346 side 14 well opened for end disc M_14circularity 0.04 / 0.08 with 2 max/min
⌾Ø538: +2 μm / +19 μmsurf. roughness inside 1.4 μm => 1.2% more RF losses
⌾Ø524: +51 μm / +104 μm
CERN YES tbd,ready
* to acceptable dimensions
PIMS production meeting 26-27 February 2013 Rolf Wegner 12
Machined parts, disc G_2-3
26.02.2013
element EDMS remarks slight deviations* serious deviations* where leak tight
cavity suited
disc G_2-3
1243398 surf. roughness <0.8
Ø538: +23 μm / + 19 μmnose length: +18 μmflatness nose tip: 47 μm
CERN YES YES,ready
* to acceptable dimensions
PIMS production meeting 26-27 February 2013 Rolf Wegner 13
Machined parts, ring G_13-14
26.02.2013
element EDMS remarks slight deviations* serious deviations* where leak tight
cavity suited
ringG_13-14
1252344 machining tests
many flatness @ welds: 87 μm / 75 μmB A:⊥ 0.114 (0.3 all cavity)
NCBJ nobut ok for short module
* to acceptable dimensions
• Ring G_13-14 was intended for machining tests to validate milling technology (spare material of CERN prototype)
• port welding defect, weld was repaired, further machining tests
• port welding defect of ring M_1-2, ring G_13-14 is used for assembly check of short module
PIMS production meeting 26-27 February 2013 Rolf Wegner 14
Machined parts, summary
26.02.2013
• discs analysed are close to acceptable dimensions=> remarkable progress made since last year (improvement of factor 5 to 10 on most tolerances) assembly diameter 524.720-0.025
+0 seem to be well under control (QA reports discs M_2-3, M_4-5, M_10-11, M_12-13)however, deviations on * coaxiality axis/524/538mm (=> inter-cavity alignment – aperture reduction)* perpendicularity axis/faces (=> inter-cavity alignment – aperture reduction)* cooling channel finishing
=> we need to analyse remaining discs of cavity M at CERN for qualification
• ring M_13-14 is close to acceptable dimensions=> remarkable progress made since last year (machining procedures were developed [weld deformation] and most acceptable tolerances reached) assembly diameter 524.720+0.050
+0.075 seem to be well under control (also ring G_13-14)however, deviations on * coaxiality 538/524mm (=> inter-cavity alignment – aperture reduction)* perpendicularity axis/faces (=> inter-cavity alignment – aperture reduction)* only 1 ring as sample
=> we need to analyse remaining rings of cavity M at CERN for qualification
PIMS production meeting 26-27 February 2013 Rolf Wegner 15
Short module: assembly test
26.02.2013
• assembly was very smooth
• only end disc M_14 was slightly difficult to place correctly, small gap remains=> Thierry will use dense point weldings before final weld
end disc M_1
ring G_13-14
disc G_2-3
ring M_13-14
end disc M_14
PIMS production meeting 26-27 February 2013 Rolf Wegner 16
Short module: RF check, preliminary results
26.02.2013
measured simulated freq. difference[kHz]
ratio meas/sim[%]
f_mode_1 [MHz] 349.756 350.500 -744
Q_mode_1 21'500 26'560 80.9
f_mode_2 [MHz] 363.308 363.970 -662
Q_mode_2 27'730 30'200 91.8
0 50 100 150 200 250 300 350 400 450 500
-0.20
0.00
0.20
0.40
0.60
0.80
1.00|Ez|^2
Mode 1, simulatedMode 1, measured
0 50 100 150 200 250 300 350 400 450 500
-0.20
0.00
0.20
0.40
0.60
0.80
1.00|Ez|^2
Mode 2, simulatedMode 2, measured
z-axis: assembly order z=0 end disc M_1 - ring G_13-14 - disc G_2-3 - ring M_13-14 - end disc M_14 … to z=max
PIMS production meeting 26-27 February 2013 Rolf Wegner 17
Short module: RF check, preliminary results
26.02.2013
• assembly had to be clamped, otherwise Q ~ 1'000, f_mode_1 ~ 349.200 MHz
• Q-values reasonable, will improve with welding (~ 10% seen for prototype)
• field profiles look very similar, slight deviations for mode 2
• ~ 700 kHz frequency difference between measurement and simulations
• simulation uncertainty ~ ± 500 kHz (mesh limit, 2 cells, different geometry)
• tuning range (island + plunger) for mechanical tolerances + simulation uncertainties: ± 600 kHz
=> further analysis needed to understand difference in frequency simulations/measurement
=> simulation model needs to be checked carefully (systematic difference 700 kHz)
measured simulated freq. difference[kHz]
ratio meas/sim[%]
f_mode_1 [MHz] 349.756 350.500 -744
Q_mode_1 21'500 26'560 80.9
f_mode_2 [MHz] 363.308 363.970 -662
Q_mode_2 27'730 30'200 91.8
PIMS production meeting 26-27 February 2013 Rolf Wegner 18
Next steps
26.02.2013
•qualification of vacuum check
* visit of NCBJ experts to CERN, March 25-26th, tests of end disc, disc, ring
* shipment of equipment to NCBJ (~ 100 kg, ~ 200 pieces, ~ 25'000 CHF)
* visit to NCBJ with CERN experts, intended before April 19th (material !)tests of end disc, disc, ring
•vacuum check of discs and rings cavity M at NCBJ
•production and checks of waveguide ring cavity M at NCBJ
•check of discs and rings cavity M at CERN => qualification for series production
•check of waveguide ring cavity M at CERN => qualification for series production
•in order to advance production, maybe intermediate green light for finishing cavity 2
PIMS production meeting 26-27 February 2013 Rolf Wegner 19
Production qualification, February 2013Status of qualifications, 25.02.2013:
Step std + central discs end discs rings WG-rings
1st rough (+2mm) ok(10.01.2012)
ok(10.01.2012)
ok(19.04.2012)
ok(25.09.2012)
2nd rough (+1mm)
ok(30.03.2012)
ok(30.03.2012)
ok(18.12.2012)
ok(25.09.2012)
final for cavity 1 (M)
ok(27.09.2012)
ok(10.05.2012)
ok(18.12.2012)
ok(25.09.2012)
final for cavity 2
vacuum check at NCBJ
final for series check discs cavity 1 (M) at CERN
check discs cavity 1 (M) at CERN
check rings cavity 1 (M) at CERN
check WG-ring cavity 1 (M) at CERN
26.02.2013