ESR 3.1 Introduction Iordan Doytchinov 26.05.2014

1. ESR 3.1 IntroductionIordan Doytchinov 26.05.2014

2. Contents: • Who am I • My MEng degree • Industrial Placements and University Projects • PACMAN project 3.1 • Optimization of the Design and Assembly of the Main Beam Quadruples (MBQ) for the CLIC Two Beam Modules – PhD thesis • Mechanical Integration of the PACMAN Assembly/Alignment Bench • Current work plan, Training • To do..

3. Me: I come from here - Sofia Beside Engineering…

4. IntegratedEngineering MEng Electrical Engineering training Mechanical Engineering training Core/Integrated Subjects Mechatronics Mechanical Design and Materials Selection Electronic Devices & Circuits Robotics Engineering Electromagnetic Fields and Waves Systems modeling/simulation Thermal and Fluid Mechanics Control Engineering Vehicles Dynamics Complex Interdisciplinary projects Engineering and Design

5. Industrial Placements Projects/MEng Thesis Siemens – Test automation - 1 year F4E – Vehicle Dynamics/ Performance - 3 months National Met Office UK: UAV Performance Estimation /system Integration Omron ltd Barcelona: Real-Time HIL robot dynamics simulator (Master THESIS)

6. PACMAN 3.1 - Objectives • Optimization of the Design and Assembly of the Main Beam Quadrupoles (MBQ) for the CLIC Two Beam Modules - main for PhD Hypothesis • Mechanical Integration of the PACMAN Assembly/Alignment Bench One off prototype example: Dominique Loiseau - the Rose de Temps clock Extremely costly on time & money High number production (thousands): ‘Swatch’ mass production of Swiss made high quality wrist watches  “If you grasp the principles – myths fall & Ideas take-off” David Lentink (TUDELFT) TED Conference Amsterdam Babylon tower by Tobias Verhaecht (1561 – 1631) (“برج خليفة‎, "KhalifaTower“) – Dubai 2010

7. I) Optimization of the MQQ Design & Assembly • Optimize magnet mechanical-magnetic design and assembly procedure from point of view of ultra precision engineering. Beam Dynamics magnetic field Spec The desired function! Our Meca! Good Field Region (GFR) Specification: - R(GFR) = 4mm - = 0.1% Component design Quadruple Yoke prototype example By Raphael Leuxe Understand relationship? Field Spec VSMechanical/Assembly spec Assembly procedure/jig (easy, cheap, fast) Quadruple Yoke prototype example By Raphael Leuxe

8. The Precision Engineering View • “There is not such thing as bad ‘function’ delivered by assembly/component. All functions are ‘perfect’ and acts according to its intentional or unintentional design. There is only a ‘bad’ or not well understood design.” • Understanding of real material geometry as function of environment and itself (temperature, gravity, coupling forces). • ‘Right’ Kinematic design (restriction of the right degrees of freedom) • The insurances of the ‘right’ measurement met • Design for repeatability. (high stiffness design – low histersis, attenuation due thermal, vibration effects). • Other..

9. Current Tasks for I) • Understanding of the ‘scale’ of the problem. Internship in Metrology department – Accuracy, Uncertainty, Resolution, Repeatability, Reproducibility and Tractability of micrometric measurement at 2m length scale. The same activity to be performed at DMP Spain! • Understanding of the current state of art – Assembly with mounting key design. • Investigation of perfect possible mechanical assembly from CMM measurement of prototype parts (KOTEM software) • Understanding of beam dynamics specification in the contexts of mechanical specification (Daniel Schulte), FEA magnet Simulation software, KOTEM • Material selection for the magnet? Investigation on best material for point of view of magnetic and high precision mechanical design (Ashby analysis)

10. II) Mechanical Integration of the PACMAN Assembly / Alignment Bench • Specifications coordination (by Iordan Doytchinov): • Act as system engineer making sure all the subgroups specification Integrate in appropriate way: • QFD analysis to be performed as practice for wire integration case study • - Understanding of the complete specification • Possible Ashby analysis for selection of hybrid material for the wire. • A GLOBAL mechanical/assembly INTEGRATION aspect (by Iordan Doytchinov) • BPM sensor mechanical alignment and integration to MBQ magnets • - BPM integrated with beam pype? • - BPM as part of the MBQ? • - Other solution such as separate stand or integration to MBQ stand

11. II) Mechanical Integration of the PACMAN Assembly / Alignment Bench • A GLOBAL mechanical/assembly INTEGRATION aspect (by Iordan Doytchinov) • Electromechanical integration of magnetic, RF and metrological wire measuring tools into single one (one wire, one stretching system)1 Wire and support structure for 2 to 4 different measurements: (RF BPM, RF ACC structures, MBQ Magnetic field position and quality, Metrological reference )

12. II) Mechanical Integration of the PACMAN Assembly / Alignment Bench • A GLOBAL mechanical/assembly INTEGRATION aspect (by Iordan Doytchinov) • To perform the full mechanical integration of the prototype alignment bench (which will fit on Leitz CMM) make sure all sensor, control actuators systems integrate electromechanically. All ultraprecision design techniques to integrate various subsystems into the final PACMAN stand

13. Current Work Plan, Training • Current work: • Study Assembling of DMP prototypes with mechanical KEY method developed • - Use KOTEM smart fit software (http://www.kotem.com/Pages/SmartFit.htm) to study best fit of components • Wire integration case study for 2x systems (Magnetic and Metrological). Practice QDF (Quality Function Deployment) and component analysis to select appropriate wire and stretching systems. • Training: • So far 3day basic ISO GD&T course; 1 day Faro arm course • To do: - 10 Day CATIA course • - 6 Day ANSYS course • - Internship Metrology department, • - High Precision engineering course at Cranfield • - Other

14. To Do • Create detailed work, training plan, define Scientific Hypothesis on Part I • Identify Risk Metrics and redesign work/training plan with accordance to it:

15. Thank you for listeningYour feedback?

16. QFD • “CUSTOMERS”: • Magnetic measurement • Mechanical Measurement • RF Measurement BPM • RF Measurement Acc structures

17. Ashby analysis Hybrid Material