4) AL-1685-4599_TS HBEND Magnets.pdf

Technical Specification for the ALS-U Storage Ring

HBEND Magnets

D. Munson, P. Wehle

Release Date: Feb 20 2024 9:02:43 AM PST

Document Number: AL-1685-4599 Revision: A

Document Status: Released

Document Type: NOTE

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Advanced Light Source Upgrade Project

Lawrence Berkeley National Laboratory All officially released LBNL documents are watermarked and contain LBNL Document Control Center release information in the lower-left corner of the document's pages.

Printed hard copies of this document are for reference only.

TABLE OF CONTENTS

Revision History

Approvals

Abbreviations and Acronyms

1 Introduction

1.1 Design parameters

1.2 Subassemblies overview

1.3 Axial PM function

2 Magnetic Specifications

2.1 Core PM blocks

2.2 Axial PM blocks

2.3 PM block mechanical property requirements

2.4 Pole pieces

3 HBEND Component and Assembly Description

3.1 Magnet core assembly

3.1.1 Components

3.1.2 Core PM block and spacer customization and selection

3.1.3 Bonding requirements and recommendations

3.1.4 Tuning block and carrier assembly

3.1.4.1 Description

3.1.4.2 Selection

3.1.4.3 Adjustment for integration into yoke assembly

3.2 Axial adjuster plate, field clamp, and yoke integration

3.2.1 Axial block selection

3.2.2 AAP function and description

3.2.3 AAP–field clamp integration testing

3.2.4 AAP–field clamp integration with magnet core assembly

3.3 Yoke–magnet core assembly integration

3.4 Full HBEND magnet assembly integration

3.5 Temperature sensors

4 HBEND Magnet Assembly Alignment and Positioning

4.1 AAP to yoke axial alignment (Z)

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4.2 Field clamp to AAP alignment

4.3 AAP vertical gap

4.4 Upper pole tip to lower pole tip alignment

5 HBEND Assembly Tooling Requirements

5.1 Splitting tooling

5.2 Field harmonic adjustment tooling

5.3 Field shunt tooling

5.4 Tuning magnet installation tooling

6 Certifications, Inspections, Testing, and Reporting

6.1 Certifications

6.2 Mechanical epoxy qualification

6.3 In-process testing

6.3.1 Mechanical inspections

6.3.2 Fiducialization measurements

6.3.3 AAP and field clamp measurements

6.3.4 Magnetic measurements

6.3.4.1 PM blocks magnetic testing

6.3.4.2 Field mapping and integral measurements

6.3.5 Harmonic adjustment tooling testing

6.4 Factory acceptance testing

6.4.1 HBEND assembly measurement

6.4.2 Motor and motion control testing

6.4.3 Magnetic measurements

6.4.4 Effective multipole content measurements with wire techniques

6.4.5 Axial adjuster magnet fiducialization

7 Applicable Documents

Appendix A: HBEND Magnetic Hazards / Assembly Forces

A1. Magnetic hazards

A2. Magnet core assembly magnetic forces

A3. Magnet core assembly–yoke assembly magnetic forces

A4. Mid-plane block to core/yoke assembly magnetic forces

A5. Tuning magnet assembly magnetic forces

A6. Axial magnet assembly magnetic forces ci al ly R el ea se d to th e

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Appendix B: Upper and Lower HBEND Assembly Integration Magnetic Forces

Appendix C: Representative HBEND Expansion Equation for Magnetic Field Definition

Appendix D: Reference for Effective Multipole Content Measurement

Appendix E: HBEND Splitting Magnetic Flux Contour Map

REVISION HISTORY

Rev. CM Number Description of Change

A Baseline

APPROVALS

Approver Project Role

Ken Chow ALS-U Chief Engineer

Bertrand Nicquevert ALS-U Technical Coordination Lead

Michael Lerche ALS-U Magnets Control Account Manager

Charles Swenson ALS-U Magnets Technical Lead

Christoph Steier ALS-U Accelerator Physics Lead

Dawn Munson ALS-U Lead Technical Representative

Windchill Approved / Concurred By mlerche,KPChow,bnicquevert,CASwenson ci al ly R el ea se d to th e

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ABBREVIATIONS AND ACRONYMS

AAP Axial adjuster plate

ACL Acceptance Criteria List

ALS-U Advanced Light Source Upgrade

Br Magnetic remanence

CoFe Cobalt iron

COTS Commercial off the shelf

FAT Factory Acceptance Test

GeV Giga electron volts

HBEND “Hard Bend” Permanent Magnet Dipole Bending Magnet

Hc Normal coercivity

Hcj Intrinsic coercivity (also: intrinsic induction) kA/m Kiloamperes per meter

LBNL* Lawrence Berkeley National Laboratory mm millimeter

N Newtons

NdFeB Neodymium iron boron

PM Permanent magnet (axial, core, pole piece)

QA Quality Assurance

SOW Statement of Work

T Tesla

TiN Titanium nitride

University* The Regents of the University of California

*For the purposes of this document, the terms University and LBNL are used interchangeably.

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1 INTRODUCTION

1.1 Design parameters

This specification document provides the technical requirements for the production of the “Hard Bend” Permanent Magnet Dipole Bending (HBEND) magnet assemblies for the

ALS-U storage ring under a build-to-print subcontract.

The HBEND magnet type is designed to provide a nominal 3.76-degree bend angle to the electron beam at energies between 1.9 and 2.0 giga electron volts (GeV). The magnetic field strength is adjusted by varying the amount of magnetic flux entering the magnet poles, which is accomplished mechanically by varying the position of axial permanent magnets (PMs).

The HBEND magnet assemblies are to be produced according to this technical specification and the applicable drawings and documents listed in Section 7.

Figure 1-1 Model of a fully assembled HBEND magnet ci al ly R el ea se d to th e

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1.2 Subassemblies overview

Figure 1-2 identifies key sub-assemblies and systems. At the center of the HBEND are the upper and lower core magnet assemblies. Each is constructed of a cobalt iron (CoFe) pole piece (blue triangle) and neodymium iron boron (NdFeB) core PM blocks: transpole

(red), trans (green), and vertical (yellow). (For a detailed view of the core magnet assembly, see Figure 3-1.) The epoxy-bonded core magnet assemblies are fitted into yokes to make up the upper and lower yoke assemblies.

The synchronous motor drive assemblies (called out on the left) position the axial adjuster plates to which the axial PMs (not shown; see Section 1.3) are bonded. Fiducial markings on components provide the means with which to reach the degree of precision required for alignment.

Figure 1-2 HBEND key subassemblies and systems

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1.3 Axial PM function

The magnetic properties of the magnet core assembly can be adjusted by positioning the axial PMs, which are bonded to axial adjuster plates (AAPs) that can be raised and lowered. The range of motion is shown in the figures below: in the 1.9 GeV operational position (Figure 1-3), the AAPs position the axial PMs away from the CoFe pole piece, and in the 2.0 GeV operational position (Figure 1-4), the axial PMs cover the CoFe pole piece.

Illustration C in both figures shows the location of the axial PMs without the AAP for illustration purposes (upper half) and fully assembled and embedded in the AAP (lower half).

Field clamps – which are shown in blue in illustration A in Figures 1-3 through 1-5 and hidden in illustrations B and C – shield nearby magnets from the HBEND’s powerful magnetic field.

Figure 1-3 Model showing the field clamps (A), AAPs (B) and axial PM location (C) in the 1.9 GeV operational position. The axial PMs, shown as light blue blocks, do not cover the CoFe pole piece.

Figure 1-4 Model showing the field clamps (A), AAPs (B) and axial PM location (C) in the 2.0 GeV operational position. The axial PMs, shown as light blue blocks, cover the CoFe pole piece.

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Figure 1-5 shows the position of the AAPs in the 2.0 GeV position (B) and in the 1.9 GeV position (C).

Figure 1-5 The HBEND in the 2.0 GeV position (B) and the 1.9 GeV position (C).

Figure 1-6 shows the axial PM block position in cross-section from the side. The arrows in the axial blocks show the direction of the magnetic field: pointing toward the pole in the upper half and pointing away from the pole in the lower half. The arrows in the vertical

PM blocks (yellow) show the direction of their magnetic field orientation: toward the pole in the upper half and away from the pole in the lower half.

Figure 1-6 HBEND cross section view with axial PM block positions:

A) Nominal 2.0 GeV position, B) 1.9 GeV position.

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2 MAGNETIC SPECIFICATIONS

The HBEND magnet core assembly consists of the following magnet types:

1) Magnets made of NdFeB (type – name, drawing number) o Core – vertical, AL-1185-9695 o Core – upper trans, AL-1153-6580 o Core – upper transfer, AL-1153-6582 o Core – lower trans, AL-1185-9693 o Core – lower transfer, AL-1185-9697 o Tuning magnet, AL-1220-4003 o Axial, AL-1185-9698

2) Pole piece made of a wrought CoFe alloy o Pole piece, AL-1207-7003

Magnetic specifications and mechanical property requirements for each magnet type are described in this section and in the applicable drawings. An overview of core and axial PM block properties is provided in Table 2-1.

Table 2-1 Core and axial PM block properties overview

Property

PM Blocks

Unit Core Axial

Finished material minimum average remanence (Br) at 20°C ≥ 1.35 ≥ 1.3 T

Finished material minimum coercivity (Hc) at 20°C ≥ 1010 ≥ 970 kA/m

Intrinsic induction (Hcj) of the bulk material ≥ 1671 ≥ 1830 kA/m

Enhanced intrinsic induction (Hcj) in the surface layers at a minimum depth of 1 mm ≥ 1989 ≥ 2228 kA/m

2.1 Core PM blocks

Core magnet blocks are those included in the upper magnet core assembly AL-1208-2802, lower core assembly AL-1195-4932 and magnet tuning assembly AL-1313-7282. The required properties for core magnet blocks are:

1. All core PM blocks contained in any one HBEND magnet assembly must be made from the same ingot/lot to ensure uniform magnetic characteristics. Traceability for each ingot and PM block is required.

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2. For core magnet blocks, the minimum average remanence (Br) of the finished material at 20C after thermal stabilization must be equal to or greater than 1.35 T.

3. For core magnet blocks, the minimum coercivity (Hc) of the finished material at

20C after thermal stabilization must be equal to or greater than 1010 kA/m

(12.7 kOe).

4. The core magnetic block material must be manufactured using a grain boundary diffusion process to enhance the intrinsic induction (Hcj) at the block surface. The value of Hcj after thermal stabilization in the bulk material must be equal to or greater than 1671 kA/m (21 kOe). The enhanced value of Hcj in surface layers at surfaces perpendicular to the magnetic orientation must be equal to or greater than

1989 kA/m (25 kOe). The enhanced Hcj surface layer must have a minimum depth of 1 mm.

5. The intrinsic induction versus magnetizing force curve ([B - 0H] versus H) must be linear in [B - 0H] to within 2.5% in the second quadrant and to at least 110% of the nominal coercive force (Hc) at 40°C after thermal stabilization.

6. The magnetized blocks must be thermally stabilized at 60°C for 3 hours in an open circuit condition prior to the testing specified in Section 6.3.4.

7. The dipole moment of each block, measured as specified in Section 6.3.4, must be within 1.0% of the average obtained for all the blocks of each type at 20C after thermal stabilization.

8. The 3-sigma variation of the dipole moment angle of each block must be within

1.0 degree at 20°C after thermal stabilization.

9. The surface magnetic fields on each block must meet the following requirement:

The magnetic field, as measured at the center of the two block surfaces perpendicular to the direction of magnetization, must be smaller or equal to ±4% of the field when measured at the distance 15 mm from the surfaces.

10. The following representative magnetization information for the material(s) offered is required:

Induction versus magnetizing force curves at both 20 and 40C.

Intrinsic induction versus magnetizing force at both 20 and 40C.

Reversible permeabilities parallel and perpendicular to the beam direction or z axis.

Reversible temperature coefficients of coercivity (Hc) and intrinsic coercivity

(Hcj).

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2.2 Axial PM blocks

Axial magnet blocks are those included in the Upper Adjuster Plate Insert Assy AL-1458-

3681 and the Lower Adjuster Plate Insert Assy AL-1635-5463.

1. All axial PM blocks contained in any one HBEND magnet assembly must be made from the same ingot/lot to ensure uniform magnetic characteristics. Traceability for each ingot and PM block is required.

2. For axial magnet blocks, the minimum average remanence (Br) of the finished material at 20C after thermal stabilization must be equal to or greater than 1.3 T.

3. For axial magnet blocks, the minimum coercivity (Hc) of the finished material at

20C after thermal stabilization must be equal to or greater than 970 kA/m

(12.2 kOe).

4. The axial magnetic block material must be manufactured using a grain boundary diffusion process to enhance the intrinsic induction (Hcj) at the block surface. The value of Hcj after thermal stabilization in the bulk material must be equal to or greater than 1830 kA/m (23 kOe). The enhanced value of Hcj in surface layers at surfaces perpendicular to the magnetic orientation must be equal to or greater than

2228 kA/m (28 kOe). The enhanced Hcj surface layer must have a minimum depth of 1 mm.

5. The intrinsic induction versus magnetizing force curve ([B - 0H] versus H) must be linear in [B - 0H] to within 2.5% in the second quadrant and to at least 110% of the nominal coercive force (Hc) at 40°C after thermal stabilization.

6. The magnetized blocks must be thermally stabilized at 60°C for 3 hours in an open circuit condition prior to the testing specified in Section 6.3.4.

7. The dipole moment of each block, measured as specified in Section 6.3.4, must be within 1.0% of the average obtained for all the blocks of each type at 20C after thermal stabilization.

8. The 3-sigma variation of the dipole moment angle of each block must be within

1.0 degree at 20°C after thermal stabilization.

9. The surface magnetic fields on each block must meet the following requirement:

The magnetic field, as measured at the center of the two block surfaces perpendicular to the direction of magnetization, must be smaller or equal to ±4% measured at the distance 15 mm from the surfaces.

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10. The following representative magnetization information for the material(s) offered is required:

Induction versus magnetizing force curves at both 20 and 40C.

Intrinsic induction versus magnetizing force at both 20 and 40C.

Reversible permeabilities parallel and perpendicular to the beam direction or z axis.

Reversible temperature coefficients of coercivity (Hc) and intrinsic coercivity

(Hcj).

2.3 PM block mechanical property requirements

1. The magnetic material used for blanks must not contain flaws that will interfere with uniform magnetic properties. That is, any hairline crack must be less than

5 mm long and 0.5 mm deep. Any chipped area cannot be larger than 0.5 mm3, and of the whole, no more than 2% of the area can be chipped.

2. The magnetic material is to be coated on all surfaces and edges with a titanium nitride (TiN) coating to prevent corrosion in a 20C and 75% humidity environment. The coating thickness must be at least 0.004 mm and must not exceed 0.008 mm.

3. All dimensions and tolerances of blocks indicated on the applicable drawing apply to the blocks after coating.

4. The block coating must be compatible with the block epoxy adhesive.

5. The Subcontractor may consider surface passivation of the PM blocks provided all exposed surfaces are first coated with a thin clear polymer film of polyurethane

(paint) to prevent corrosion. However, the process description must be submitted to LBNL for review and approval before it is used.

6. Each block must be identified by a unique serial number as indicated on the applicable drawing.

2.4 Pole pieces

1. All pole pieces must be fabricated from a wrought iron-cobalt alloy that meets all requirements per ASTM Standard A801-21 Alloy Type 1, UNS R30005.

2. The pole pieces for any one HBEND magnet assembly must be made from the same ingot/lot to ensure uniform magnetic characteristics. Traceability for each ingot and pole piece is required.

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3. The pole pieces must undergo a magnetic anneal heat treatment to maximize DC magnetic properties in accordance with the Subcontractor’s experience and the guidelines established by ASTM A801-21. The magnetic anneal must be performed after machining of all planar surfaces, just prior to the final precision pole tip machining.

4. The pole piece dimensions specified in drawing AL-1207-7003 are applicable after magnetic annealing is complete.

3 HBEND COMPONENT AND ASSEMBLY DESCRIPTION

3.1 Magnet core assembly

3.1.1 Components

The HBEND magnet assembly includes an upper and a lower magnet core assembly, each of which consists of a CoFe tapered magnet pole piece around which an array of NdFeB core PM blocks is epoxy bonded. Each PM block type is bonded together in sets of three.

Each set consists of the three blocks that achieve the required magnetic properties and dimensions. Block corners have a chamfer to mitigate chipping and demagnetization effects.

Figure 3-1. Configuration of PM block types, pole piece, and spacer block within a magnet core assembly.

PM block type # required

Core assembly HBEND magnet

Vertical 3 6

Corner / transfer 6 12

Transverse 6 12 ci al ly R el ea se d to th e

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Once the core magnet assembly is fabricated, the spacer block (if needed) is machined to provide the required final dimensions based on magnetic measurements.

Non-magnetic steel shoes are bonded onto the outside of the core. They provide a mechanical interface to prevent damage to the magnet core assembly during installation and to support the vertical magnetic loads on the core through a contact interface with the mid-plane blocks that provide the interface between the upper and lower yoke assemblies. The internal surface of the shoe is tapered to provide an epoxy-bonded load interface that captures the permanent magnet core in transverse compression when the upper and lower yokes are joined. The shoes also provide mounting points for tooling, alignment pins, and fiducials for alignment work. As shown in Figure 3-2, there are 6 spot-faces in each side shoe. These are used to adjust transverse alignment and rotation of each core.

Figure 3-2 Fully constructed magnet core assembly.

3.1.2 Core PM block and spacer customization and selection

Each magnet core assembly contains one spacer block (AL-1339-0493) positioned on the vertical PM blocks. The spacer and vertical PM block size and height will be customized based on the measured magnetic characteristics of the magnetic core PM blocks. The vertical blocks must be produced so that their initial height is equal to the combined heights of the PM block (AL-1185-9695) and spacer (AL-1339-0493).

PM materials are specified with a minimum range of magnetic remanence per Section 2.

The magnetic remanence in a production batch of PM blocks can be up to 5% higher than ci al ly R el ea se d to th e

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PM materials to allow selection of PM blocks with uniform magnetic properties.

The baseline CAD model has a spacer integrated into the core assemblies to mitigate the uncertainty in magnetic remanence between production batches of PM blocks. The combined height of the vertical PM block together with the spacer represents the vertical

PM block height that would be required with a core assembly of PM blocks at the specified minimum allowed remanence.

No spacer is required if the PM materials properties are at minimum specification. A shorter vertical PM block would be required should the PM production batch material have a higher magnetic remanence. The design intent is that the height of the vertical blocks is adjustable before final core assembly.

Per Section 6.3.4.1, effective magnetic remanence will be measured by the Subcontractor on all PM blocks to understand the performance of the PM production batch. An effective remanence will be estimated from magnetization and surface field measurements on the

PM blocks. LBNL will model core performance using measurement data to determine vertical block and spacer height.

LBNL will specify a spacer height and vertical PM block height for each magnet assembly after review of the data to achieve the desired magnetic core performance. The dimensions of a core’s transverse and corner blocks must remain as specified in the baseline design. The vertical PM blocks must be ground to final dimension and coated after LBNL specifies the vertical PM block height.

3.1.3 Bonding requirements and recommendations

Significant magnetic forces are anticipated during the bonding process; refer to Appendix

A for information regarding hazards associated with these forces and best practices to manage them.

Before beginning the bonding process, all required magnetic and mechanical measurements per the Statement of Work (SOW) AL-1685-4598 must be submitted to

LBNL for review and approval. In addition, both the surface preparation process – particularly at the pole piece-PM block interface – and the epoxy bonding process must be submitted to LBNL for review and approval before they are used.

The recommended production process for core PM blocks is that they are individually produced, then coated with TiN. The final vertical PM block sizes will be specified by

LBNL after reviewing the magnetization data.

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The first step in the magnet core assembly is to bond all of the like magnet shapes together into their respective stacks of three. A complete epoxy cure cycle is required between each gluing process. Specific glue line tolerances are indicated on the associated drawings, AL-1208-2802 and AL-1195-4932. Figure 3-3 illustrates the recommended bonding sequence. The numbers in the figure correspond to these steps:

1) Bond the interface between the pole piece and the vertical PM blocks.

2) Install and bond the transverse PM block assemblies onto the pole piece sides.

3) Install and bond the corner or transfer block assembly on one side.

4) Install and bond the corner or transfer block assembly on the other side.

5) Bond the spacer (if required) block to the vertical PM and corner/transfer PM blocks.

6) Install the side shoes.

7) Install the top shoe.

Figure 3-3 Recommended magnet core bonding sequence.

3.1.4 Tuning block and carrier assembly

3.1.4.1 DESCRIPTION

PM tuning blocks are used to mitigate the uncertainty in the magnetic field due to variation in material properties and assembly tolerancing. There are two tuning magnet carrier assemblies per magnet core assembly, as shown in Figure 3-4.

The tuning range of these assemblies is roughly +/- 0.6 % of the main dipole field for the full field blocks, and ~0.3% for the ½ length blocks. This enables a resolution of ~0.06% ci al ly R el ea se d to th e

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During integration the Subcontractor will cross check the upper and lower yoke dipole field integrals.

Per LBNL drawings, spare tuning blocks and aluminum spacers must be supplied by the

Subcontractor to support field adjustments if needed at LBNL.

Figure 3-4 (left) Tuning magnet carrier assembly with 5 PM tuning block magnets.

(right) Magnet core assembly with tuning magnet carrier assembly installed.

3.1.4.2 SELECTION

The Subcontractor must complete magnetic measurements of each core’s magnetic field in the pole tip region per Section 6.3.4.2 and PM tuning blocks per Section 6.3.4.1 for

LBNL review. Based on this data, LBNL will provide a PM array configuration for each tuning carrier assembly. After installation of the carrier assemblies, the Subcontractor will perform a second measurement per Section 6.3.4.2 and document the results of the carrier assembly installation.

3.1.4.3 ADJUSTMENT FOR INTEGRATION INTO YOKE ASSEMBLY

The Subcontractor must, after core integration in the upper and lower yokes, complete magnetic measurements of each integrated yoke assembly's magnetic field in the pole tip region per Section 6.3.4.2 for LBNL’s review. Based on this data, a second adjustment to the carrier permanent magnet array configuration may be required and LBNL will provide a specification for the second adjustment. If an adjustment is required, the Subcontractor will perform a final measurement after reinstallation of the carrier assemblies per Section

6.3.4.2 to document the results of the carrier assembly adjustment.

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3.2 Axial adjuster plate, field clamp, and yoke integration

3.2.1 Axial block selection

The Subcontractor must complete magnetization measurements on the axial PM blocks per Section 6.3.4. Based on this data, LBNL will specify the axial magnet block configuration within each AAP assembly.

3.2.2 AAP function and description

Each HBEND magnet assembly has four AAP assemblies that are moved synchronously to adjust the magnetic dipole field intensity. Field adjustments are required to set the nominal dipole field for 2.0 GeV or 1.9 GeV beam operations and for temperature compensation. The primary function of each AAP is to accurately position the bonded axial PM blocks with respect to the pole gap in both the fixed <z> axis (in and out), and to allow precision motion control of the axial PM blocks in the vertical <y> axis of the magnet (up-and-down). The axial PM blocks are epoxy bonded into a machined pocket in each of the four AAP assemblies.

Each AAP assembly has a mechanical interface to a set of two linear guide rails on the yoke assembly. The linear guide rails ensure transverse alignment of the AAP and positioning of the axial PMs, as described in Section 4. Synchronous motor driven actuators connect to the AAP assemblies at each side of the upper/lower HBEND magnet assembly. The linkage is accomplished via a mechanical drive carriage that connects the motor actuators to both the front and back APP assemblies for the corresponding upper or lower assembly. There is provision for limit switch mounts on the upper and lower upstream AAP plates. As shown in Figure 3-5, the AAP also functions as an installation appliance (carrier) for the field clamps.

AAP and field clamp integration proceeds in two phases:

● AAP integration testing. This phase assists in the validation of the machined interfaces on the yoke, AAP, and field clamp assemblies, including the guide rail alignment and motor drive interfaces without magnet materials present. (See

Section 3.2.3.)

● Integration including axial PMs and the magnet core assembly.

Significant magnetic forces exist between the axial magnets and both the field clamp and the magnet core during the integration. (See Section 3.2.4.)

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Figure 3-5 AAP key features (Z-axis PM adjuster plates).

3.2.3 AAP–field clamp integration testing

The integration process described below must be completed by the Subcontractor. Figure

3-6 illustrates the installation of the AAP and field clamp plates.

A. Each yoke assembly half must be oriented with the core side down to enable installation tooling integration. In this way the tooling fits onto the top of the upper yoke assembly and onto the bottom of the lower yoke assembly. Each yoke assembly has a set of integrated and aligned linear rails for AAP assemblies. To begin AAP installation, a set of four linear guide rail extensions are affixed to the tooling and yoke guide rails. The design has sufficient degrees of freedom to enable alignment with the yoke’s fixed linear guide rails. The assembly tool rails are aligned to the linear guide rails on the yoke assembly via bridging pins. Alignment is validated by sliding the linear rail carriages up and down both sets of rails, per

Figure 3-6A.

B. To install the AAP, the yoke linear guide carriages are moved to the tooling rails.

Support for the AAP is provided by the top tooling plate while the fasteners are installed into the guides. Alignment is again confirmed by moving the AAP across the length of both rails, per Figure 3-6B.

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Figure 3-6 AAP/field clamp plates installation, conceptual illustration:

(A) Tooling assembly installed on yoke assembly. Carriages (in green) shown mounted onto linear rails. (B) AAPs installed onto the tooling fixture. (C) Field clamp plates integrated onto the AAP assemblies. (D) Motor assemblies installed onto the yoke assembly.

C. To prepare for the installation of the field clamp, the AAP is moved to the top of the tooling for support. Two dowels are installed onto the AAP for support while the field clamp is secured with fasteners. A final alignment check is completed with both plates installed by moving them along the length of both rails, per Figure

3-6C.

D. Install the motor actuator drive assemblies to the yoke assembly per Figure 3-6D.

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Each motor drive actuator assembly consists of a motor, an encoder, and four limit switches to support control diagnostics. Limit switches are located at both the minimum and maximum axial PM adjuster plate gap positions. Each motor drive assembly has upper and lower limit switches. The multiple limit switch pairs, common to each motor, function redundantly for the control system. Figure 3-7 shows the motor drive assembly with the major components labeled. Limit switches will be initially positioned to match the anticipated motion range defined by the baseline design. (See Section 4.3.)

Figure 3-7 Motor actuator drive assembly major components

Encoder linear guide mounting hardware and limit switch brackets are designed with reference edges and pins for reproducible alignment positioning. The yokes have mechanically machined interfaces, enabling rapid installation of the motor drives.

After mounting the motor assemblies, the motor drive carriage is moved to its maximum outer position. The AAP/field clamp plates are then moved to contact the motor actuator drive carriage, allowing the linkage bolts to be installed. The motor drive actuator assembly is then used to move the AAP/field clamp plates into position to anchor the field clamps to the yoke. A work instruction and testing procedure will be provided by LBNL for motor integration and testing.

When aligned with the mounting face holes, the field clamp plate is lifted off the APP carrier and secured to the yoke assembly using six threaded spacer assemblies that anchor to the yoke. The dowels and installation fasteners linking the field clamp plate are removed during this operation. (See Figure 3-8.) The tooling is then removed and the rail end clamps are installed.

Motor

Encoder Assy

Linear guide with custom carriage

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Figure 3-8 (A) Installation of the gap separation between the AAP and field clamp (FC) plates after install. (B) Identification of threaded field clamp support spaces.

(C) Detailed view of field clamp threaded spacer assemblies.

3.2.4 AAP–field clamp integration with magnet core assembly

The final integration process of the AAP and field clamp to the yoke-core assembly differs from the integration testing process due to the significant magnetic forces and hazards created by the magnet core assembly, as described in Appendix A. To protect personnel and equipment, the assembly tooling and motor drive assembly must be used.

The following process requires that the yoke and magnet core assembly are already integrated, as described in Section 3.3. To begin, each yoke assembly half must be oriented with the core side down to enable installation tooling integration. In this way the tooling fits onto the top of the upper yoke assembly and onto the bottom of the lower yoke assembly. To accommodate the magnetic forces, the AAP and field clamp are assembled onto the yoke-core assembly tooling and connected to the motor drive assembly before lowering over the magnet core assembly. The motor drive assembly must be fully operational to enable a controlled field clamp installation. The motor drive actuator and carriage linkage are designed to manage the magnetic forces during assembly integration.

Figure 3-9 illustrates the configuration during the AAP and field clamp installation process with the magnetic core installed.

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Figure 3-9 Installation of the AAP and field clamp with magnet core installed.

3.3 Yoke–magnet core assembly integration

The Subcontractor must employ tooling to enable core positioning and manage magnetic forces per Section 5.2 and Appendix A.

Before the magnet core assembly is installed, the upper and lower core and yoke assemblies require mechanical inspection data to determine a shimming plan. A second set of dimensional measurements will need to be taken after each core integration to adjust and validate core positioning and the final adjusted heights of the mid-plane blocks. The mid-plane blocks are to be ground to their final vertical height at this point in the assembly process.

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Figure 3-10 illustrates the configuration of the HBEND magnet’s upper and lower yoke assemblies. The yoke is not directly coupled to its corresponding magnet core assembly;

a Z-axis alignment slot engages a pin on the core’s outer shoe assembly (shown in Figure

3-11). The pin alignment slots on the yoke are designed to allow each core’s transverse x position to be adjusted using transverse set screw positioners. The set screws allow transverse positioning and rotations about the alignment pin axis. The pin alignment slots have large counter bores to allow access with Allen key tooling, as indicated in Figure 3-11.

Alignment of the magnet core assembly position within each yoke assembly is dictated by the overall alignment requirements of the upper and lower pole tips (see Section 4.4).

Figure 3-10 Yoke assembly key components.

The magnet core assembly is shimmed in the vertical plane to ensure that the mid-plane shoe interface engages the yoke’s mid-plane blocks during the mechanical installation.

The mid-plane blocks slide in the transverse plane during installation. During assembly, the mid-plane blocks are in compressive contact with the core side plates due to magnetic forces. Four torqued fasteners clamp each of the mid-plane blocks to the yoke. Shimming is somewhat imprecise with granular steps of ~12 microns anticipated. The mid-plane blocks will require surface grinding during final assembly to match the shimmed interfaces.

During mid-plane block installation there are attractive loads to both the yoke and core interface surfaces. These attractive forces ensure that proper mid-plane block contact is achieved between the yoke and shoe surfaces. Fasteners are installed and torqued to fix the mid-plane blocks in place onto the yokes. The resultant traction loads hold the mid-plane blocks in place, locking the core into the yoke.

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Figure 3-11 Magnet core assembly and yoke integration with alignment features.

Side and vertical shims may be used in addition to the set screw positioners. The transverse positioning set screws can then be further locked in compression with additional torque.

3.4 Full HBEND magnet assembly integration

There are significant magnetic forces associated with this integration; refer to Appendix A for magnet handling best practices, hazards, and magnetic force calculations. Splitting tooling must be used to support the integration of the upper and lower HBEND assembly

(See Section 5.1).

Figure 3-12 illustrates the final steps in the full HBEND assembly integration once the upper and lower yoke assemblies are fully constructed:

A. The lower HBEND assembly is integrated/mounted onto the base support assembly per Figure 3-12-A.

B. The splitting tooling assembly is installed onto the assembly base and used to lower the upper assembly onto the lower assembly, per Figure 3-12-B.

C. Once the upper and lower HBEND assemblies are fully seated, the linkage plates are installed as shown in Figure 3-12-C. (Final steps not shown: cabling and fiducial mount installation.)

Z-axis alignment pin

Magnet core shoe

Pin alignment slots (6 per side)

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Figure 3-12 Full HBEND integration sequence: A) the lower assembly is installed on the base assembly.

B) The upper assembly is lowered onto the lower assembly with the splitting tooling provided by LBNL.

C) Fully constructed HBEND magnet assembly (cabling not shown).

3.5 Temperature sensors

The HBEND design incorporates five precision thermal sensors per magnet assembly.

The upper and lower magnet core assemblies are each fitted with two sensors located on the mounting shoes. A fifth sensor is included in each assembly to measure ambient air temperature.

4 HBEND MAGNET ASSEMBLY ALIGNMENT AND POSITIONING

4.1 AAP to yoke axial alignment (Z)

The AAP must deviate by no more than 100 microns in the plane parallel to the yoke face

(z-direction) and move freely through the full range of motion as it goes up/down the rails when installed on each yoke assembly. As shown in Figure 4-1 and per drawing AL-1615-

8572, the nominal distance between the yoke and AAP is 0.5 mm.

4.2 Field clamp to AAP alignment

The distance between the AAP and the field clamp must not deviate by more than

250 microns. As shown in Figure 4-1 and per drawing AL-1615-8572, the nominal gap between the AAP and field clamp is 2.88 mm. The gap has an engineered margin to manage uncertainty in field clamp assembly positions.

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Figure 4-1 Nominal gap for AAP-to-yoke and field clamp-to-AAP (mm).

4.3 AAP vertical gap

AAP gap requirements are summarized in Table 4-1. All measurements must be verified by the Subcontractor. The motor controls system enables offset adjustment and control of the upper and lower AAP assemblies individually with respect to the gap. The gap is measured between the closest upper and lower axial magnet surfaces.

Figure 4-2 AAP gap illustrated.

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Table 4-1 AAP Vertical Gap and Alignment Requirements

Gap Position / Alignment Dimension (mm)

Upper Axial PM Alignment to Pole Tip Gap Centerline ± 0.05

Lower Axial PM Alignment to Pole Tip Gap Centerline ± 0.05

AAP Gap Centerline (equidistant from the upper and lower pole tips) within ± 0.05

Inner Axial Adjuster Plate Hard Stop Gap 12.0

Inner Ball Screw MIN GAP HARD STOP (Adjustable) 16.0

Motor Controls, Power Off, Inner Safety Limit Switch #1 Gap 17.0

Motor Controls, Stop, Inner Limit Switch #2 Gap 19.0

Motor Controls Stop, Outer Limit Switch #3 Gap 159.0

Motor Controls, Power Off, Outer Safety Limit Switch #4 Gap 161.0

Outer Ball Screw Hard Stop (Adjustable) Gap 162.0

4.4 Upper pole tip to lower pole tip alignment

Achieving the final alignment for the HBEND upper and lower assembly pole tips is critical, and the required measurement values are provided in the applicable drawings.

The values listed in Table 4-2 are for reference only.

Table 4-2 Upper and lower pole tip (1 mm radii) gap and alignment

Location per AL-1207-7003 coordinate system Distance / tolerance (mm)

Pole tip gap (y-direction) 10.06 ± 0.05

Pole tip center alignment (x-direction) 0.00 ± 0.05

The alignment can be inspected in-situ using a laser tracker with non-magnetic spherical mount retroreflectors interfacing with the conical fiducial points A-F on each HBEND pole. The AAPs can be extended sufficiently far from the midplane to enable this inspection.

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5 HBEND ASSEMBLY TOOLING REQUIREMENTS

HBEND production requires the use of specialized tooling that will be provided by LBNL and must be used as directed by LBNL. No modifications or tooling changes can be made to any LBNL-provided tooling without LBNL review and written approval. The

Subcontractor may submit alternative tooling designs that meet the requirements specified below but may not implement them without LBNL review and written approval.

5.1 Splitting tooling

The HBEND splitting tooling facilitates the separation of the upper assembly from/to the lower assembly.

5.2 Field harmonic adjustment tooling

LBNL will supply tooling to flip and support the upper and lower assemblies to enable core repositioning. This tooling is required because the mid-plane blocks must be loosened to allow for core position adjustment.

Only lateral x-axis positional adjustments are required for the cores. The lateral adjustment range is ± 0.400 mm with a positioning resolution of 10 micrometers.

LBNL personnel are available to offer alignment assistance for the measurements at the

Subcontractor’s site during critical assembly and alignment steps.

5.3 Field shunt tooling

LBNL will provide magnetic field shunt assembly / field distribution tooling that reduces the stray field flux intensity around the split poles.

If the Subcontractor prefers to submit a design for alternative tooling for LBNL review and approval, it must meet the following requirements:

● Tooling will reduce the magnet flux for the upper and lower HBEND assemblies

AL-1195-5051 and AL-1210-1565 to the levels shown in the magnet flux contour map in Appendix D.

● Upper and lower magnet core components must be mechanically protected after separation.

● Tooling must be compatible with the splitting tooling (after the upper assembly has been split from the lower assembly).

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5.4 Tuning magnet installation tooling

Tuning magnet installation tooling must be used to install and remove individual tuning magnets and tuning carrier assemblies at all relevant locations on the upper and lower magnet cores and on the integrated upper and lower core-yoke assemblies.

LBNL will provide tooling to enable tuning PM block removal and replacement. The

HBEND design requires that the HBEND magnet is split and that the AAP and field clamp plates are removed prior to changing the tuning magnets.

If the Subcontractor prefers to submit a design for alternative tooling for LBNL review and approval, it must meet the following requirements:

● Tooling must be compatible for use with both upper and lower core assemblies, and with the upper and lower core assemblies after core-yoke assembly integration.

● Access to both tuning carrier assemblies is required; a tooling or carrier orientation change is acceptable to access both carrier assemblies.

● Tooling must mitigate magnetic forces on the carrier assembly during installation and removal of the tuning magnet carrier assemblies into the upper and lower

HBEND assembly to ensure personnel and equipment safety.

● Tooling must allow for installation and extraction of individual permanent magnet tuning blocks in the carrier assemblies.

6 CERTIFICATIONS, INSPECTIONS, TESTING, AND REPORTING

Reporting requirements are described and summarized in SOW AL-1685-4598. This section provides information needed to meet reporting and Quality Assurance (QA) requirements.

6.1 Certifications

The following must be provided for all materials and commercial off the shelf (COTS) parts and components:

Certifications (e.g. material certifications)

Certificates of conformance

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