ED0024313---_PIP-II Procurement and Fabrication Specification_Tuner Stepper Motor Actuator.pdf

PIP-II Procurement and Fabrication Specification, Stepper Motor Actuator for Tuners

Author: Donato Passarelli

Document Number: ED0024313 Rev -

Document Approval Date Approved

Originator Donato Passarelli As in TC

Checker Yuriy Pischalnikov As in TC

Checker HyeKyoung Park As in TC

Checker Saravan K. Chandrasekaran As in TC

Checker Mattia Parise As in TC

Checker Joe Ozelis As in TC

Approver Cristian Boffo As in TC

PIP-II

Procurement and Fabrication Specification

Document Title: PIP-II Procurement and Fabrication Specification - Stepper Motor Actuator for Tuners

Fermi National Accelerator Laboratory 2

Document Title: PIP-II Procurement and Fabrication Specification - Stepper Motor Actuator for Tuners

Fermi National Accelerator Laboratory 3

Revision History

Author Revision Date Description of Change

Document Title: PIP-II Procurement and Fabrication Specification - Stepper Motor Actuator for Tuners

Fermi National Accelerator Laboratory 4

Table of Contents

1 Scope 5

2 Procurement Specification 5

2.1 Bidding Phase 5

2.2 Technical and Cost Evaluation Phase 6

2.3 Execution Phase and Hold Points 6

2.3.1 Hold Points 7

2.3.2 Delivery Requirements 7

3 Fabrication Specification 7

3.1 Technical Specifications 7

3.2 Quality Controls at manufacturer’s premises 8

3.2.1 Materials certifications 9

3.2.2 Metrology Controls 9

3.2.3 Testing 9

3.3 Quality controls at Fermilab 10

3.4 Cleaning, Packaging, and Shipping 10

4 Appendix 12

Document Title: PIP-II Procurement and Fabrication Specification - Stepper Motor Actuator for Tuners

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1 Scope

This document describes the requirements necessary to specify and procure the stepper motor actuator for tuners, in quantity as indicated in Table 1.

Description Quantity

Stepper motor actuator for tuners 103

Table 1: Item(s) description and quantities

The stepper motor actuator for tuners is a system that translates rotational motion to linear motion. It usually constitutes of stepper motor, gear box, spindle, and traveling nut as shown in Figure 1.

The stepper motor actuator is integrated in mechanism named “tuner” that is used to adjust the resonant radio-frequency of Superconducting Radio Frequency (SRF) cavities to the nominal value, after the cooldown from room temperature to 2K.

The Manufacturer shall provide all materials necessary to fabricate complete deliverables. The

Manufacturer shall provide manufacturing engineering services required to generate internal shop drawings and all documentation needed to manage and support their suppliers. The Manufacturer shall provide all labor to assemble, test, and supervise the manufacture of all components regardless of where these are made: within the manufacturer’s plant or in a second facility or sub-contractor. Any information of a proprietary nature must be identified in the bid response.

2 Procurement Specification

Purchase Order will be owned and managed by Fermilab Research Alliance (FRA).

2.1 Bidding Phase

Bidder shall provide Quotation including all costs to deliver the assembly indicated in Table 1, along with the following documentation:

a) Schedule that meets a lead time of 12 months, starting from the date that the FRA Purchase Order is awarded to the bidder running through fabrication, including hold points reported in Table 2.

Supporting documentation, to demonstrate that the bidder will deliver within the specified timeframe, is recommended.

b) Technical Proposal to demonstrate the ability of the bidder to deliver the assembly with performance that meet or exceed Fabrication Specification reported in section 3 of this document. Example of past projects (within the last five years) that closely match the scope in

Document Title: PIP-II Procurement and Fabrication Specification - Stepper Motor Actuator for Tuners

Fermi National Accelerator Laboratory 6 complexity and value, and that best illustrate the bidder’s capability, experience, and performance will be considered for the technical evaluation.

c) Management Control Plan to demonstrate the ability to ensure the required quality standard throughout the entire execution of the project. Examples of quality documentation developed for past projects (within the last five years) to will be considered for the technical evaluation.

All required documentation shall be organized with a table of contents and corresponding sections.

Delivered Duty Paid (DDP) Incoterm 2020 rules shall be applied as method of delivery.

2.2 Technical and Cost Evaluation Phase

Proposals will be reviewed by technical and cost evaluation teams, after which an FRA purchase order will be awarded to the successful bidder.

2.3 Execution Phase and Hold Points

Upon FRA purchase order award, the Manufacturer shall assign a person responsible for the technical execution and Quality Control (QC) of the project, and a person responsible for the commercial follow-up, throughout the duration of the contract. They shall be able to communicate in English.

Within two weeks from FRA purchase order award, a kick-off meeting shall be scheduled to initiate technical and commercial discussion between the technical and commercial representatives from FRA and the Manufacturer. Action items from the meeting shall be addressed within one week.

Upon conclusion of the kick-off meeting, FRA expects to receive bi-weekly a status report via e-mail (FRA will provide a template) from the manufacturer. Also, a monthly meeting held by videoconference shall be regularly scheduled to discuss technical and commercial updates. The meetings will be held in English.

However, FRA representatives are always available to respond any time if questions will arise.

Within four weeks from FRA purchase order award and before starting any fabrication and procurement activity, the Manufacturing Readiness Review (MRR) shall be organized to allow FRA reviewers to assess the Manufacturer’s level of preparation to proceed to the manufacturing and procurement phase.

Review’s recommendations (if any) based on the presented material (see MRR deliverables in Table 2), shall be addressed within two weeks from the conclusion of the MRR.

Upon conclusion of the MRR, the Manufacturer will be allowed by FRA to proceed with the fabrication and procurement phase. Quality Controls (see section 3.3) and technical reports, as detailed in Table 2, shall be provided by the Manufacturer to FRA.

The readiness to ship the unit shall be assessed through an appropriate review.

Document Title: PIP-II Procurement and Fabrication Specification - Stepper Motor Actuator for Tuners

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2.3.1 Hold Points

A Hold Point is defined as the moment in time wherein the process needs to be stopped to allow an FRA representative to perform reviews and QCs deemed necessary.

Table 2 lists the main hold points and associated documentation deliverables for this project.

Hold Point

Description Deliverables When required

A Kick-off Meeting

Introduction to the scope and requirements Updated schedule

Datasheet and expected performance of the actuator

Within 2 weeks from FRA purchase order award and before starting any Fabrication and Procurement

B

Manufacturing Readiness Review(s)

(MRR)

Detailed drawings of the unit’s interfaces List of materials to be used

Datasheet and expected performance of the actuator Wiring configuration and pinout

Detailed MIP and Travelers’ template (see section 3.2) Plan for cleaning, packaging, and shipping (see section 3.4)

Within 4 weeks from FRA purchase order award and before starting any Fabrication and Procurement

C Shipping

Readiness Review

Materials certifications (see section 3.2.1) Reports of metrology controls (see section 3.2.2)

Reports of Testing and Measurements (see section 3.2.3) Discrepancy report(s) (If applicable)

Reports of cleaning, packaging, and shipping (see section 3.4)

Prior to final delivery

Table 2: Hold Points and Documentation Deliverables for Fabrication Phase

2.3.2 Delivery Requirements

All units indicated in Table 1 shall be delivered to Fermilab along with all documentation required, specified in Table 2, within 12 months from the date that the FRA Purchase Order is awarded to the bidder.

Delivery in one or multiple batches could be accepted.

3 Fabrication Specification

This section provides technical specifications, quality controls, and shipping plan requirements.

3.1 Technical Specifications

The stepper motor actuator shall work in the range of pressures from atmospheric pressure to high vacuum (1·10-8 mbar), and in the range to temperatures spanning from room temperature down to 4K.

The unit shall be able to deliver an axial force equal or greater than 1300N.

The stepper motor shall be 2-phase (winding) type, have low flux leakage rotor, and operate at 24V and

1.2A nominal.

Dry lubricants only shall be used.

Figure 1 schematically shows the required the main physical interfaces and sizing of the envelope.

Document Title: PIP-II Procurement and Fabrication Specification - Stepper Motor Actuator for Tuners

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An interface (heat dissipator) to mount a copper heat-sink strap to remove the heat generated by the motor during operation shall be provided.

A resistance temperature detector (RTD) platinum 100 (Pt100) shall be embedded in the stepper motor windings. The RTD will be used to monitor the temperature of the stepper motor and avoid overheating.

The materials used for the fabrication of the entire stepper motor actuator, including wiring, shall not have mild to moderate radiation damage below 1.0 MGy. Therefore, all materials used should be revised an approved by Fermilab representative(s) at the MRR (see Table 2).

Each stepper motor actuator shall be equipped with a pair of limit switches type S15-276 (see Figure 2) manufactured by Jaidinger Mfg. Co., 1921 W. Hubbard St, Chicago, IL 60522.

Hypertronics circular plastic connectors shall be used to terminate the wiring and serve as cabling interface. A 4-pin male type connector, serial number # D01PB406MSUTH by Hypertac Hypertronics, shall be used to terminate the RDT wires. A 9-pin male type connector, serial number #

D02PB906MSUTH by Hypertac Hypertronics, shall be used to terminate the motor and limit switches.

FRA will provide the wiring configuration based on the design of the proposed actuator at the time of the MRR.

Manufacturer shall permanently etch the serial number on each unit. The etching shall take place on the exterior surface of the housing. The format of the serial number shall be approved by FRA at the MRR.

Figure 1 Schematic representation of the stepper motor actuator, interfaces, and envelope.

3.2 Quality Controls at manufacturer’s premises

The Manufacturer shall prepare a project specific Manufacturing and Inspection Plan (MIP) for FRA’s approval. The MIP shall list the sequence of manufacturing steps, as well as the associated inspections.

The Manufacturer shall develop quality control procedures and tests to guarantee that the project will be in full conformance with the FRA’s specifications. If during inspections a discrepancy occurs, the supplier shall generate a Discrepancy Report (DR) and obtain FRA’s approval before proceeding to the subsequent step.

Document Title: PIP-II Procurement and Fabrication Specification - Stepper Motor Actuator for Tuners

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The Manufacturer shall maintain records of all inspections and tests in the form of Quality Reports (i.e., electronic travelers).

The MIP shall be made available for FRA’s reviews and approval by the Manufacturing Readiness Review

(MRR), as also indicated in Table 2.

3.2.1 Materials certifications

Certified Mill Test Reports (CMTR) of all raw materials used to fabricate deliverables shall be provided to

FRA as part of the deliverables of the shipping readiness review (see Table 2). These material certifications shall include all processes and tests with grade and composition being clearly identifiable and traceable to the respective component.

If the vendor obtains components from a subcontractor, the vendor is responsible to prove that the materials and welds for the components meet compliance requirements.

3.2.2 Metrology Controls

CMM measurements shall be performed, and certificate of dimensional control shall be provided for all details that will be identified as critical mechanical interfaces during the MRR.

3.2.3 Testing

Prior to shipping, the manufacturer shall test the following characteristics for each unit and provide a written report.

• Resistance

Measure the resistance of each phase windings at both room temperature and submerged in liquid nitrogen. Required value is 2.65 ± 10 % Ω.

• Inductance

Measure the inductance of each phase winding at 1 kHz at both room temperature and submerged in liquid nitrogen. Required value is 7 ± 10 % mH.

• Dielectric strength

This test shall be performed to check the isolation between the different components inside and outside of the stepper motor body. The resistance should be greater than 100 MΩ between each phase winding, between phase windings and the housing, and between RTD and the phase windings.

• Detent torque

The detent torque is defined as the amount of torque the stepper motor produces when the phase windings are not energized. The torque is mainly caused between the interaction of the permanent magnets of the rotor and the stator slots of the permanent magnet. The detent torque is measured at room temperature with the magnetized rotor. Required value is 19 ± 20% N·mm.

Document Title: PIP-II Procurement and Fabrication Specification - Stepper Motor Actuator for Tuners

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• Holding torque

The holding torque is measured at 24 V, rated current and both clockwise and counterclockwise direction. The holding torque should be greater than 0.34 Nm.

• Starting current with gear in liquid nitrogen (unloaded)

The starting current is the minimum current necessary to accelerate the motor to the specified speed from a standstill, achieving a homogenous rotation. The starting current with no load should be 10 to 20 % of the rated current at a speed of 400 Hz, 24 V, and in full step mode.

• Starting current with gear in liquid nitrogen (loaded)

Record the starting current with a load of 400 N at 400 Hz, 24 V, and in full step mode.

3.3 Quality controls at Fermilab

FRA reserves the right to perform additional QC inspections on the delivered units, such as:

• Visual inspection of shipping package

• Visual inspection of the units

• Measurements of resistance

• Measurement of the RTD Pt 100 resistance

• Measurement of the stepper motor rotations

• Wiring verification

Acceptance of the final product will be granted by FRA only after verification of the requirements and approval of documentation listed in Table 2.

3.4 Cleaning, Packaging, and Shipping

Each unit shall be free from dust and grease. Each assembly shall be packaged such that the wires are well separated from each other and not damaged in transit.

All the components shall be prepared for shipment in accordance with commercial practice and in compliance with applicable rules and regulation pertaining to the handling, packaging, and transportation of the product to ensure carrier acceptance and safe delivery. Each component shall be individually wrapped in low density polyethylene bags.

Wooden or plastic containers that prevent impact damage and bending shall be used. Sharp fasteners that penetrate the container, such as nails or screws, shall be avoided, and in any event, provisions shall be made that inadvertent penetration of points cannot come into contact with the components. Banding shall be applied in such a way that the bands must be removed if the container is opened. A marking shall

Document Title: PIP-II Procurement and Fabrication Specification - Stepper Motor Actuator for Tuners

Fermi National Accelerator Laboratory 11 be applied to the bands that identifies the manufacturer or manufacturer’s shipping agent, so as to indicate if the bands may have been replaced (e.g. as a result of customs inspection).

The manufacturer shall inform the customer of the shipping configuration and the configuration shall be agreed by the Shipping Readiness Review, as detailed in Table 2.

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4 Appendix

Figure 2 Drawing of the limit switch S15-276 by Jaidinger Mfg. Co.