AL-1887-9848A.pdf

ALS-U SR HBEND Actuator Assembly and Testing Work Instructions

J. Hekmat, P. Mallon, D. Arbelaez

Release Date: Apr 9 2026 12:24:51 PM PDT

Document Number: AL-1887-9848 Revision: A

Document Status: Released

Document Type: NOTE

Category Code: AL7510

ALS-U - STORAGE RING

MAGNETS - GENERAL

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Downloaded by: Martha Gamarano Grausz at May 08, 2026 08:54:03

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Advanced Light Source Upgrade Project Lawrence Berkeley National Laboratory

Latest version of this document can be found in the LBNL Document Control Center.

A hardcopy of this document is for reference ONLY.

TABLE OF CONTENTS

Revision History

Approvals

Abbreviations and Acronyms

Introduction

Purpose

Scope

Reference

Tools required

Work Instruction

1 Overview

2 Drive Actuator Assembly

3 Drive Actuator Load Testing

4 Completion

Verification Signoff Sheet

REVISION HISTORY

Rev. CM Number Description of Change A Initial Revision

APPROVALS

The following individual(s) shall approve this document:

Approver Project Role Diego Arbelaez HBEND Production Technical Lead Soren Prestemon ALS-U Magnets CAM Windchill Approved / Concurred By darbelaez,soprestemon

ABBREVIATIONS AND ACRONYMS

ALS Advanced Light Source ALS-U Advanced Light Source Upgrade LBNL Lawrence Berkeley National Laboratory SR ALS-U Storage Ring ci al ly R el ea se d

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HBEND Hard bend dipole permanent magnet

INTRODUCTION

The ALS-U SR HBEND magnets use a servo motor-driven actuator system to adjust the strength of the magnetic field by sliding axial adjuster plates vertically. Four actuators are installed on each HBEND magnet.

PURPOSE

The purpose of this work instruction is to guide the assembly of a single actuator unit.

SCOPE

This WI describes the assembly of the mechanical components of the actuator unit. It also describes the process to test the actuator unit under mechanical load up to 2,000 N.

REFERENCE

● AL-1828-1699: ACTUATOR, HBEND

TOOLS REQUIRED

Include the list of tools required.

2.5mm Allen wrench

3mm Allen wrench

4mm Allen wrench

11mm open end wrench

16-20 Spanner (hook wrench)

Retaining ring pliers

Pin spanner for holes on the face to fit 2 mm dia. holes with a 17 mm separation

Calibrated Torque screwdrivers or wrenches with range between 4.4 and 17 in-lbs

WORK INSTRUCTION

1 OVERVIEW

1. Assign assembly number and attach label per assembly print.

2. Enter the following information on the Verification Signoff Sheet:

a. Serial number from step one

b. Work instructions number and revision ci al ly R el ea se d

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c. Start date

d. Serial numbers of all component parts to be used in the assembly

2 DRIVE ACTUATOR ASSEMBLY

This section covers the step-by-step process for assembling the drive actuators.

1. Install dowel pins into the following parts as defined in drawing AL-1828-1699: AL-

1828-1676, AL-1828-1677, AL-1828-1673, AL-1828-1689. Ensure that the pins bottom out on their corresponding part.

2. Apply Loctite 401 to the external threads of the Peek nut, AL-1828-1679, and install it into the nut housing, AL-1828-1676, turning it with a pin spanner wrench until the part bottoms out.

3. Commence work on the linear guide system. Notice the Linear Rail Base (AL-1828-

1673) is asymmetrical. One of the surfaces where the linear rails are mounted has a raised edge, this is the RIGHT side.

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4. NOTE: The Linear Rails and Slide Bearings come assembled. DO NOT REMOVE THE

SLIDE BEARINGS FROM THE LINEAR RAILS! The ball bearings in the slide bearings are NOT mechanically attached, they are held in place by the viscosity of the lubricating grease.

5. Use M3 x 0.5 x 10mm SHCS to affix one of the Linear Rails (AL-1828-1737) to the

Linear Rail Base while holding it firm against the raised edge mentioned in step 1. This is the FIXED rail. You will need to move the Slide Bearings to access all screws. The torque on the M3 x 0.5 is 7 in-lbs.

6. Loosely affix the other Linear Rail on the LEFT side using the same style hardware, run the screws in until they’re just below flush with the top of the rail; DO NOT TIGHTEN.

This is the FLOATING rail. You will need to move the Slide Bearings to access all screws.

7. Position the Linear Rail Base with the BACK facing you, position the Nut Housing with the flush side of the Peek Nut (AL-1828-1679) towards the back. Loosely affix the Nut

Housing (AL-1828-1676) to the 4 Slide Bearings using M3 x 0.5 x 8mm SHCS (HW-

1001-8825) and flat undersized M3 washers (HW-1001-8747); DO NOT TIGHTEN.

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8. While squeezing the carriages towards the nut housing reference edges, slowly tighten the screws on the Slide Bearing that is riding on the FIXED rail. The torque on the M3 x

0.5 is 7 in-lbs.

9. While squeezing the carriages towards the nut housing reference edges, slowly tighten the screws on the slide bearing that is riding on the FLOATING rail. The torque on the

M3 x 0.5 is 7 in-lbs.

10. While sliding the Nut Housing along the length of the rails, slowly tighten the screws on the FLOATING rail. If you feel any increase in friction while tightening the screws, back off and try again. The torque on the M3 x 0.5 is 7 in-lbs.

VERIFICATION POINT 1

Ensure linear bearing assembly moves freely with minimal friction

11. Screw the Lead Screw (AL-1828-1692) into the Nut Housing.

12. Loosely attach the Radial Support (AL-1828-1675) using M3 x 0.5 x 10mm SHCS and flat undersized M3 washers to the Linear Rail Base.

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13. Slide Radial Bearing (HW-1001-8385) onto the 9mm long bearing journal on the lead screw and use the 10 mm Retaining Ring (HW-1001-8393) to secure it in place.

14. Slide the Radial Bearing into the Radial Support, then tighten the M3 SHCS holding the

Radial Support to the Linear Rail Base. Move the Lead Screw axially to ensure the Radial

Bearing goes in smoothly to the Radial Support. The torque on the M3 x 0.5 is 7 in-lbs.

15. Loosely attach the Axial Support (AL-1828-1674) using M3 x 0.5 x 10mm SHCS and flat undersized M3 washers to the Linear Rail Base.

16. Slide two Angular Bearings (HW-1001-9167) onto the 17.5mm long bearing journal on the Lead Screw. Ensure the arrows on the Angular Bearings are facing each other.

17. Slide the Angular Bearing into the Axial Support, then tighten the M3 SHCS holding the

Axial Support to the Linear Rail Base. Move the Lead Screw axially to ensure all bearings smoothly enter and exit their respective supports.

18. Loosely attach the Clamp Plate (AL-1828-1678) to the Axial Support using M4 x 0.7 x

12mm SHCS (HW-1001-8938) and M4 belleville washers (HW-1001-6125).

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19. Spin the Lead Screw (use the coupling in step 26 to make spinning the rod easier) and note the movement. There should be very little friction and the rotation should feel smooth (remove the coupling if used).

20. Use a centering tool (similar to the picture below) to center the Clamp Plate to the Axial

Support.

21. While centered, slowly tighten each of the 4 M4 SHCS incrementally to ensure the

Clamp Plate is distributing its force evenly across the Angular Bearings. Use a 4 bolt torque pattern and increase torque incrementally. The torque on the M4 x 0.7 is 17 in-lbs.

22. Remove the centering tool and spin the lead screw to ensure the rotation is still smooth.

23. Slide the Locknut Spacer (Al-1828-1684) on the Lead Screw on the Clamp Plate side, followed by the Locknut (HW-1001-8325) with the nylon threads facing out.

24. Using a 11mm open end wrench and a 16-20 hook wrench (spanner) to tighten the locknut onto the Lead Screw. The hook wrench will be up against the clamp plate while tightening.

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25. Place the 2mm x 2mm x 10mm key (HW-1001-8786) into the Lead Screw keyway.

26. Install coupling (AL-1828-1690) onto the Lead Screw. Tighten the screw on the Lead

Screw side of the Coupling. The torque on the M2.5 x 0.45 is 4.4 in-lbs.

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VERIFICATION POINT 2

Ensure that the motor coupling can rotate with minimal effort

27. Affix an End Stop Shim and the End Stop Long Block (AL-1828-1683) to the Axial

Support using M3 x 0.5 x 12mm (HW-1001-8829) and M3 Undersized Washers. The

End Stop Shim should be in between the Axial Support and the End Stop Long Block.

The torque on the M3 x 0.5 is 7 in-lbs.

28. Affix an End Stop Shim (AL-1828-1690) and the End Stop Short Block (AL-1828-1682) to the Radial Support using M3 x 0.5 x 10mm (HW-1001-8827) and M3 Undersized

Washer. The End Stop Shim should be in between the Radial Support and the End Stop

Short Block. The torque on the M3 x 0.5 is 7 in-lbs.

29. Affix the Carriage (AL-1828-1677) to the Nut Housing using M4 x 0.7 x 22mm SHCS

(HW-1001-8944) and M4 Bellville washers (HW-1001-6125). The torque on the M4 x

0.7 is 17 in-lbs.

30. Affix the Coupling Housing (AL-1828-1680) to the Axial Support using M3 x 0.5 x

20mm SHCS (HW-1001-8932) and Undersized Flat M3 Washers. The torque on the M3 x 0.5 is 7 in-lbs.

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31. Affix the Motor Flange (AL-1828-1681) to the Coupling Housing using M4 x 0.7 x

12mm SHCS (HW-1001-8938) and Undersized Flat M4Washers. The torque on the M4 x

0.7 is 17 in-lbs.

32. Affix the Servo Motor (AL-1828-1745) to the Motor Flange using M5 x 0.8 x 18mm

SHCS (HW-1001-9305) and M5 Belleville Washers. The torque on the M5 x 0.8 is 35 in-lbs.

33. Tighten the screw on the motor side of the Coupling. The torque on the M2.5 x 0.45 is

4.4 in-lbs.

VERIFICATION POINT 3

Ensure that the motor coupling can rotate with minimal effort with a single finger ci al ly R el ea se d

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3 DRIVE ACTUATOR LOAD TESTING

This section covers the motion and load testing process for the drive actuators. The picture below shows an example of a testing fixture which includes the drive actuator mounted to a base plate along with the linear encoder. The drive actuator is load tested using a mechanism with two springs that are sliding inside of a bearing (with two spacers on either side), which are constrained by two stops that include load cells for measuring the applied force. The following section covers the steps required for the testing of the drive actuators.

1. If a load test fixture is used as in the picture above, the first steps will be done without load. Ensure that the force application mechanism is disengaged. In the example above, the stop block could be removed.

2. Operate drive actuator, AL-1828-1699, without external load through entire range in 5 mm steps and record the positions. The linear encoder positioning error should be less than 5 μm. The entire range is defined by starting at a distance of 1 mm from the left hardstop and stopping at a distance of 1 mm from the right hardstop. The step size can modified for the last step to avoid colliding with the hardstop.

VERIFICATION POINT 4

Ensure that the drive actuator can operate over the entire range with a position error of less than 5 μm in each step

3. If a load test fixture is used as in the picture above, the next step will be done with load.

Ensure that the force application mechanism is engaged. In the example above, the stop block with the load cell will be in place.

4. Operate the drive actuator in 1 mm steps while engaging the springs. Record the linear encoder position value at each step and ensure that it is less than 5 μm. Continue with the steps until the load reaches a maximum value of 2,000 ± 100 N. The step size can be reduced as the maximum load is approached to avoid excessive load.

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VERIFICATION POINT 5

Ensure that the actuator can drive an external load of 2,000 ± 100 N with position error of less than 5 μm

4 COMPLETION

1. Package any remaining loose components from drawing AL-1828-1699 and record the corresponding serial numbers in the Verification Signoff Sheet.

2. Ensure all component serial numbers are entered in the Verification Signoff Sheet.

3. Enter the completion date and temperature in the Verification Signoff Sheet.

4. Have Verification Signoff Sheet signed and dated by Quality Assurance.

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VERIFICATION SIGNOFF SHEET

VERIFICATION MUST BE DONE BY AN ENTITY OTHER THAN THE ASSEMBLY TECHNICIAN

ASSEMBLY NUMBER:

ASSEMBLY DESCRIPTION:

SERIAL NUMBER:

ASSEMBLY START DATE: ASSEMBLY COMPLETION DATE:

WORK INSTRUCTIONS NUMBER AND REVISION:

COMPLETE ASSEMBLY VERIFIED BY (Sign and Date):

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Table 1 Verification checklist

VERIFICATION

POINT

RECORDED INFORMATION

(As Noted)

VERIFICATION

RESULT: PASS/FAIL

(Note NCR# if applicable)

VERIFICATION BY

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Table 2 As built BOM

PART NUMBER DESCRIPTION

QUANTITY

REQUIRED

SERIAL NUMBER(S)

AL-1828-1673 BASE WITH INSERTS, ACTUATOR, HBEND 1

AL-1828-1674 AXIAL SUPPORT WITH INSERTS, ACTUATOR,

HBEND

AL-1828-1675 RADIAL SUPPORT, ACTUATOR, HBEND 1

AL-1828-1690 END STOP, SHIM, ACTUATOR, HBEND 2

AL-1828-1682 END STOP, SHORT BLOCK, ACTUATOR, HBEND 1

AL-1828-1683 END STOP, LONG BLOCK, ACTUATOR, HBEND 1

AL-1828-1680 COUPLING HOUSING, ACTUATOR, HBEND 1

AL-1828-1681 MOTOR FLANGE, ACTUATOR, HBEND 1

AL-1828-1745 SERVO MOTOR, 70MM FLANGE, 2 STACK, IEC

MOUNT, RESOLVER, 500MM CABLE

AL-1828-1692 SCREW, LEAD, 0.5-20, ACTUATOR, HBEND 1

AL-1828-1684 SPACER, LOCKNUT, ACTUATOR, HBEND 1

AL-1828-1679 NUT, PEEK, ACTUATOR, HBEND 1

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AL-1828-1678 CLAMP PLATE, ACTUATOR, HBEND 1

AL-1828-1676 NUT HOUSING, ACTUATOR, HBEND 1

AL-1828-1677 CARRIAGE, ACTUATOR, HBEND 1

AL-1828-1691 BRACKET, CABLE, ACTUATOR, HBEND 1

AL-1828-1685 BRACKET, READ HEAD, ACTUATOR, HBEND 1

AL-1828-1686 RISER, ENCODER BODY, HBEND 1

AL-1828-1757 EXTENDED RISER, ENCODER BODY, HBEND 1

AL-1828-1687 ADAPTER, ENCODER BODY, HBEND 1

AL-1828-1688 BRACKET, SWITCH, ACTUATOR, HBEND 2

AL-1828-1689 BRACKET, SWITCH, MOVING, ACTUATOR,

HBEND

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