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Undulator Control Module. Facility Advisory Committee June 17, 2008 SLAC - Controls Group. Undulator Controls - design team, APS. Josh Stein - Control System CAM Steve Shoaf - Lead engineer Eric Norum - RTEMS support / Consulting Bob Laird - Electronics Layout

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undulator control module

Undulator Control Module

Facility Advisory Committee

June 17, 2008

SLAC - Controls Group

undulator controls design team aps
Undulator Controls - design team, APS
  • Josh Stein - Control System CAM
  • Steve Shoaf - Lead engineer
  • Eric Norum - RTEMS support / Consulting
  • Bob Laird - Electronics Layout
  • Ned Arnold - Technical supervision
  • Sharon Farrell - Technical support
  • Rich Voogd - Electronic Interface/Cable Design
undulator controls slac
Undulator Controls, SLAC
  • Arturo Alarcon
  • Ernest Williams
  • Till Straumann
  • James Bong
undulator controls
Undulator Controls
  • The LCLS undulator line consists of a series of 33 identical undulator segments. The control and monitoring equipment for each segment will reside in a 19” rack located beneath each undulator girder. Three separate units will be housed in that rack – the Motor Power/AC interlock chassis, the Undulator Control Module, and the Undulator Control Module Interface chassis.
undulator segment aisle side

BFW

Undulator Segment (Aisle side)

Quad/Corrector

BPM

Translation Stage

Electronics Rack

CAM Mover

undulator segment wall side
Undulator Segment (Wall side)

EIA(Raceway)

Vacuum chamber

undulator group
Undulator group
  • The entire LCLS undulator hall consists of 33 total Undulator segments broken into 11 groups of three.

Short breaks

Long break

undulator control module interface ucmi
Undulator Control Module Interface (UCMI)
  • Provides a wiring interface between the Undulator Control Module (UCM), the interlock chassis, the Undulator motor power supplies and the temperature, position and control field wiring.
  • Provides translation stage comparator circuits and calibration adjustments
  • Contains RTD modules to acquire temperature inputs from 12 RTD’s
  • Housed in a 3U high, 12 inch deep, 19 inch rack chassis
ucmi temperature monitor
UCMI Temperature Monitor
  • Uses DataForth 12 RTD modules
    • Provides excitation for 3-Wire RTD’s using matched current sources
    • Isolation
    • Filtering
    • Amplifies
    • Linearization
  • Inputs from 3 DB15 connectors
    • 12 RTD’s

Connection to UCM via SCSI II cable

ucmi motion control
UCMI Motion Control
  • Motor Interface
    • Interface between UCM, 42 Volts Motor Power Supply and 7 Motors
      • Five CAM movers motors
      • Two Translation stage motors
      • All motors fused with 10A Slow-blow fuses
      • Use of bus bar wire for 42 VDC from Power connector to individual motor connectors and fuses.
translation stage position monitoring
Translation Stage Position Monitoring
  • Translation error logic detects excessive skew
    • Level 1 error signal relayed to UCM
    • Level 2 error signal relayed to UCM and opens solid state relay contacts to Interlock Chassis
    • Alignment procedure uses front panel trim pots, voltage monitor test points and LED’s.
      • Trim pots adjust reference voltage to comparators
beam finder wire bfw
Beam Finder Wire (BFW)
  • Connects 24VDC CMD Signal from UCM to BFW connector
  • Connects 2 limit switches from BFW to UCM
  • Connects BFW potentiometer signals to UCM
  • Provides precision 5VDC reference signal to BFW position potentiometer
  • Provides 24VDC to BFW
position monitoring
Position Monitoring
  • Provides 5VDC precision voltage reference to 8 linear potentiometers that monitor girder position and to 5 rotary potentiometers that monitor CAM position. Connects potentiometer wipers to UCM.
front panel adjustments indicators and test points
Front Panel Adjustments, Indicators and Test points
  • Alignment Offset Adjust
    • Adjusted for Zero Volts when the Translation stages are aligned
  • Level 1 Threshold Adjust
    • Adjusted for the desired skew
  • Level 2 Threshold Adjust
    • Adjusted for the desired skew
  • Alignment Offset +TP/-TP Test points
    • Test points to read the alignment offset from the positive and negative reference voltages. Both should be Zero Volts when aligned.
  • Level 1 and Level 2 Threshold Test points
  • TDS0 and TDS1 Test points
    • Differential Analog signals proportional to the amount of skew between the translation stages. Only one output will be non-zero, indicating the direction of the skew
  • Ground - reference
cont front panel adjustments indicators and test points
Cont. -Front Panel Adjustments, Indicators and Test points
  • LED Level 1 Fault
  • LED Level 2 Fault
  • LED Stop. Indicates E-Stop signal received from Interlock chassis
  • LED +5V. Directly connected through resistor to 5VDC regulator
  • LED -5V. Directly connected through resistor to -5VDC regulator
  • LED 5V Reference. Directly connected through resistor to 5VDC precision voltage reference.
  • LED 24V. Directly connected through resistor to 24VDC input.
  • LED 40VA. Directly connected through resistor to 42VDC input that powers the CAM motors.
  • LED 40VB. Directly connected through resistor to 42VDC input that powers the Translation motors.
eia electronic interface assembly
EIA - Electronic Interface Assembly
  • Purpose
    • Provide interface for electronic cabling from undulator hardware to instrumentation rack
    • Accommodate miscellaneous undulator wiring by means of auxiliary cabling channel
  • Design Criteria
    • Provide orderly cable routing from undulator hardware to instrumentation rack
    • Provide natural grouping of specific cable types
    • Reduce total number of cables entering instrumentation rack from undulator hardware
    • Reduce down time associated with cabling when repairing/replacing undulator hardware
    • User friendly system cabling installation/removal
    • Aesthetically pleasing to overall system design
eia electronic interface assembly1
EIA - Electronic Interface Assembly
  • Cabling Functions
    • Motion control - 2 translation stages & 5 CAM movers
    • Position readout - 5 rotary & 8 linear potentiometers
    • Emergency stop - 4 pushbuttons & 4 translation limit switches
    • Temperature monitoring - 12 Resistive Thermal Devices (RTD’s)
    • Beam Finder Wire (BFW) - solenoid control & position readout
undulator segment wall side1
Undulator Segment (Wall side)

EIA (Raceway)

UIR (Undulator Instrumentation Rack)

undulator hardware cabling design
Undulator Hardware Cabling Design
  • Assessing Cabling Requirements
    • Undulator hardware identification
      • establish nomenclature
    • Determination of routing (thru EIA or direct) to rack
    • Introduction of emergency stop capability (motor power)
    • Determining EIA & Undulator Instrumentation Rack (UIR) location
  • Specifications of Connector & Cable Type
    • Choosing connector types
      • Quality & ease of installation/removal
      • Connector type varies per function requirements
    • Choosing cable types
      • Selected for function (power, signal, control, etc.)
      • Specifying custom cable where applicable
undulator hardware cabling design1
Undulator Hardware Cabling Design
  • Planning for Cable Routing
    • Determination of appropriate routing along girder support system
    • Routing to junction boxes ‘A’ & ‘B’
    • Motor cables routed directly to Undulator Instrumentation Rack (UIR)
    • Determination of individual cable lengths
  • Cables Types & Quantities (49 cables total / undulator)
    • 7 motor power (2 Translation & 5 CAM movers)
    • 4 emergency stop pushbutton
    • 2 translation limit switch
    • 5 rotary potentiometer
    • 8 linear potentiometer
    • 12 temperature (RTD’s)
    • 2 Beam Finder Wire (BFW)
    • 9 Instrumentation Rack
undulator hardware system wiring
Undulator Hardware System Wiring
  • Overall Wiring Plan
    • Hardware to electronic interface assembly
    • Hardware to instrumentation rack cabling
    • EIA to instrumentation rack cabling
  • Electronic Interface Assembly Internal Wiring
    • All cables route thru EIA with exception of motor cables
    • Reduction of cables to instrumentation rack
      • Emergency stop - from 6 to 1
      • Rotary potentiometers - from 5 to 2
      • Linear potentiometers - from 8 to 2
      • RTD’s - from 12 to 3
      • Beam Finder Wire (BFW) - from 2 to 1
    • Reduced total quantity by 24 / undulator
undulator hardware system wiring1
Undulator Hardware System Wiring
  • Junction Box ‘A’ & ‘B’ Cabling
    • Hardware cable entry to junction boxes
      • 18 cables entering junction box ‘B’
      • 15 cables entering junction box ‘A’
  • EIA to Instrumentation Rack Cables
    • 1 emergency stop
    • 2 rotary potentiometers
    • 2 linear potentiometers
    • 3 temperature (RTD’s)
    • 1 Beam Finder Wire (BFW)
motor power interrupt chassis design
Motor Power/Interrupt Chassis Design
  • Chassis Functions
    • Provide motor power for translation stages & CAM movers
    • Provide power for Undulator Control Module Interface (UCMI)
    • Emergency motor power interrupt / status indication
    • Interacts with UCMI - status & control
  • Power Supply Selection & Power Distribution
    • 2 42V DC / 20A power supplies for 7 motors
    • 1 24V DC / 1.2A power supply for UCMI chassis
  • Emergency Stop Circuitry
    • 4 emergency stop pushbuttons (key reset) on girder support
    • 4 translation limit switches - in / out (upstream & downstream)
    • Translation stage skew signal - level 2 fault from UCMI
motor power interrupt chassis design1
Motor Power/Interrupt Chassis Design
  • Interfacing With The UCMI
    • Powers UCMI chassis with 24V DC
    • Provides 42V DC to UCMI for powering 7 motors
    • Receives fault status (normally closed contact) from UCMI
    • Sends ‘E-Stop’ status (motor power normal / interrupted) to UCMI
  • Status Indicators / Test Points
    • Front panel LED’s to indicate status
      • 1 24V DC supply
      • 2 42V DC supplies
      • LED’s to indicate status (normal / fault) of motor power
    • Front panel test points to monitor all 3 power supplies
smart motor power supply information
Smart Motor / Power Supply Information
  • Smart Motor Specifications
    • Animatics Model SM2320D - PLS
      • Integrates a motion controller, amplifier, and feedback encoder in the back of a high quality brushless DC servo motor
    • Animatics Motor Ratings
      • Continuous Torque - Tc 38 oz - in
      • Peak Torque - Tp 90 oz - in
      • Torque Constant - Kt 8.92 oz - in/A
      • No Load Speed 7820 rpm
      • Voltage Constant 6.6 V / K rpm
      • Peak Current Ip = Tp / Kt

Ip = (90 oz - in) / (8.92 oz - in/A)

Ip = 10.09 A

      • Continuous Torque Ic = (38 oz - in) / (8.92 oz - in/A)

Ic = 4.26 A

smart motor power supply information1
Smart Motor / Power Supply Information
  • Power Supply Requirements
    • Linear unregulated DC voltage 22 to 48 Volts DC
    • Animatics model PS42V20AF110 42 Volts DC @ 20 Amps
    • Only one supply required to operate all 7 Smart Motors
    • Shunt recommended for back EMF protection
      • 12.5 OHM 100 Watt shunt (2)
      • 1 for each power supply
    • 24 Volt DC linear regulated power supply for UCMI power
      • PowerOne HB24-1.2-A 24 Volt DC @ 1.2 Amps
undulator control module ucm functionality overview
Undulator Control Module (UCM) - Functionality Overview
  • Motion control of five undulator CAM movers and two translation stages
  • Position readback of various potentiometers distributed around the undulator girder, including interlocking logic of the translation stages
  • Temperature monitoring of RTDs distributed around the undulator
  • Control of the Beam Finder Wire diagnostic including position readback
ucm requirements
UCM - Requirements
  • Limitation of motor positioning
    • “soft limits” imposed by software
    • Limit switches to disable motor movement
    • Limit switches to remove motor drive power
    • Emergency stop signal from the AC interrupt/interlock chassis
  • Translation stage control and skew interlocks
    • Control of two independent translation stages
    • Interlock function to prevent unintentional skew of the strongback
  • Internal diagnostics to monitor the operation of the undulator controls
ucm hardware design
UCM - Hardware Design
  • Commercially available VME hardware for IOC
    • Motorola processor
    • Industry Pack Modules (ADC, RS-232, Digital I/O)
    • Responsible for
      • motion control
      • position readbacks
      • translation stage position monitoring
      • temperature monitoring
      • Beam Finder Wire control and position readback
  • Undulator Control Module Interface (UCMI ) Chassis
    • Field wiring connection interface
    • Connects to IOC via high density 50 pin SCSI-II cables
  • Motor Power/AC Interrupt Chassis
    • Terminates motor power for emergency stop buttons or translation stage skew
ucm motion control
UCM - Motion Control
  • LCLS Undulator Support/Mover System Engineering Specification (#1.4-112)
    • CAM motion details
    • Translation stage motion details
  • APS EPICS motor record device support
    • Animatics SmartMotors
  • UCMI Chassis
    • Field wiring interfaces directly to all motors, not through junction box
    • Houses circuit board to distribute power and serial I/O to each motor
      • Serial I/O and motor power via hybrid cable
    • Houses translation stage skew monitor circuit
ucm position readbacks
UCM - Position Readbacks
  • Eight linear potentiometers for girder position monitoring
    • Manufacturer: novotechnik
    • Model: TR10
  • Animatics Smart Motor internal encoder readback for CAM position
  • Five Rotary potentiometers for CAM position monitoring
    • Manufacturer: novotechnik
    • Model: P2200
  • Two linear potentiometers for translation stage position monitoring
    • Manufacturer: novotechnik
    • Model: TRS100
  • Two undulator translation limit switches
    • Manufacturer : Micro-Switch (Honeywell)
    • Model: 11SM1
ucm girder position monitoring
UCM - Girder Position Monitoring
  • Eight linear potentiometers monitoring girder position
    • Independent position feedback of the girder at each location
    • 1kΩ potentiometer
    • Independent linearity of ± 0.25%
    • Independent repeatability of 10µm
  • Precision voltage source used for the potentiometers for accurate measurements
    • Analog Devices AD586 (5V ± 2.5mV)
  • Long term power supply drift compensation
    • Dedicated ADC channel to monitor precision power supply output
  • Loopback configuration for motion control is possible
    • Not currently implemented, SUT results showed single motion always in spec.
  • Characterization with 16-bit ADC
    • Need 13 bits of resolution to obtain ±2 micron readback over 10 mm range
    • Characterization will be done during Long Term Test (LTT)
ucm cam position monitoring
UCM - CAM Position Monitoring
  • Rotary potentiometers monitor CAM positions (indirectly monitor quad position)
    • 5 kΩ potentiometer
    • 360° of mechanical travel
    • 345° of electrical travel
    • Independent linearity of ± 0.1%
    • Independent repeatability of less than 0.01 degrees
  • Transformation matrix used to calculate the center of the downstream quad
  • Precision voltage source used for potentiometers for accurate measurements
  • Long term power supply drift compensation
    • Dedicated ADC channel to monitor precision power supply output
  • Characterization with 16-bit ADC
    • Need 13 bits of resolution to obtain ±0.05° readback over 360°
      • 2µm of quad linear motion ~0.05° of CAM motion
    • Characterization results have yielded resolutions of 0.01°
ucm translation stage position monitoring
UCM - Translation Stage Position Monitoring
  • Two linear potentiometers monitoring translation stage positions
    • Independent position feedback of the two translation stages
    • 5kΩ potentiometer
    • Independent linearity of ± 0.075%
    • Independent repeatability of 10µm
  • Precision voltage source used for the potentiometers for accurate measurements
  • Long term power supply drift compensation
    • Dedicated ADC channel to monitor precision power supply output
  • Characterization with 16-bit ADC
    • Need 13 bits of resolution to obtain ±15 micron readback over 100 mm range
    • Characterization will be done during Long Term Test (LTT)
  • Two undulator translation limit switches
    • Connected to the Animatics Smart Motor limit switch inputs
    • Two additional limits wired directly to the AC Interrupt Chassis
ucm translation stage skew monitoring
UCM - Translation Stage Skew Monitoring
  • Translation stage comparator circuit inside the UCMI Chassis
    • Two levels of transverse skew interlock intervention
      • Level 1 threshold, when motion begins to get outside of acceptable alignment
        • UCM enters alarm state which requires operator intervention
        • One motor individually moved to match other motors position
      • Level 2 threshold, if the magnitude of the skew continues
        • AC interrupt chassis is tripped, cuts power to all motors
        • UCM enters alarm state which requires engineering intervention
    • Calibrated alignment of stage positions
      • Level 1 and Level 2 have a single alignment adjustment
      • Level 1 and Level 2 have independent threshold adjustments
  • Level 2 violation will require a tunnel access to visually inspect the problem
    • Motion interlock clear button on Motor Power/AC Interrupt Chassis
      • Allows movement of translation stages to clear the fault
ucm temperature monitoring
UCM - Temperature Monitoring
  • Twelve RTD sensors positioned on girder assembly
    • Vendor: Omega
    • Model: RTD-830 surface mount
  • UCMI Chassis
    • Field wiring interface for all RTD’s
    • Interfaced to Dataforth RTD modules inside chassis
      • RTD excitation voltage
      • Isolates, filters, amplifies and linearizes a single channel of temperature input
ucm temperature monitoring1
UCM - Temperature Monitoring
  • Ambient temperature monitoring around girder
  • 3 wire RTD’s
    • Longer wire operating lengths (not an issue with this installation)
      • 2 wire configuration can be up to 100m, 3 wire configuration can be up to 600m
    • Minimizes lead wire resistance effects
    • Platinum element
      • High accuracy (a typical 100 ohm sensor is nominally 0.385 ohm/°C)
      • Low drift
      • Fast response (extremely thin film)
      • Linear resistance-temperature relationship
      • Wide temperature operating range (-60 to 260 °C)
  • Characterization with 16-bit ADC
    • Need 13 bits of resolution to obtain ±0.05 °C readback over 320 °C range
    • Characterizationwill be done during Long Term Test (LTT)
ucm beam finder wire controls
UCM - Beam Finder Wire Controls
  • A 24V dc signal activates BFW solenoid
  • Two limit switches for IN/OUT position readback
  • Linear potentiometer used to verify “IN” position accuracy
    • Same linear potentiometer as used to monitor the girder position
  • UCMI Chassis
    • Field wiring interface for solenoid
    • Field wiring interface for IN/OUT limit switches
    • Field wiring interface for linear potentiometer
      • Position verification
undulator segment aisle side1

LP2-Y

LP3-X

Undulator Segment (Aisle side)

LP6-Y

LP7-X

T06

TM2

TM1

LP8-TR

LP4-TR

T10

RP2

T11

RP5

CMx = CAM Motor

TMx = Translation Motor

RPx = Rotary Potentiometer

LPx = Linear Potentiometer

Txx = Temperature RTD

RP3

CM2

CM3

T12

T04

CM5

undulator segment wall side2
Undulator Segment (Wall side)

LP1-Y

T05

T03

T09

LP5-Y

T02

RP1

CMx = CAM Motor

TMx = Translation Motor

RPx = Rotary Potentiometer

LPx = Linear Potentiometer

Txx = Temperature RTD

T08

CM1

T07

T01

CM4

RP4

ucm hardware platform
UCM - Hardware Platform
  • VME IOC Hardware
    • Hybricon Crate (SLAC specifications)
      • Remote console access
      • Remote monitoring of voltage and fan
      • Remote reboot and power cycling
    • Motorola mvme3100 Processor (approved by SLAC)
      • RTEMS based IOC
        • Currently testing with a MVME6100 processor
        • BSP for MVME3100 processor being developed at SLAC
    • Acromag IP330A Industry Pack Module (ADC)
    • GE Fanuc (SBS) IP-OCTAL-232 RS-232 Communications (Motors)
    • GE Fanuc (SBS) IP-OPTOIO-8 Digital I/O (BFW solenoid/limit switches)
    • 4 industry pack slots with 3 populated by above modules
  • 2U height
ucm software development environment
UCM Software - Development environment
  • Subversion (SVN) controlled software repository
  • EPICS base R3.14.9
    • asyn R4-9 rs232 communications to motors
    • autosave R4-2-1 ioc pv saving
    • ip330 R2-5 potentiometer and RTD readbacks
    • ipUnidig R2-5 BFW solenoid and limit switches
    • ipac R2-9 industry pack modules support
    • motor R6-3 Animatics smart motors
    • seq 2.0.11* smart monitor sequence programs
  • RTEMS 4.7.1 in IOC
  • VisualDCT (VDCT) for database development
    • Using .vdb file extension to denote VDCT database

* Library reference for iocsh needs to be removed from Makefile, it’s been consolidated into another library

ucm software motion equations configuration control
UCM Software - Motion Equations Configuration Control
  • Motor Algorithm Document
    • Controlled document
    • References mechanical drawings of CAM wedge angles/configuration
    • Mechanical drawings will reference Motor Algorithm Document
      • Mechanical changes impact the controls motion algorithm
  • EPICS database
    • Relevant process variables will reference the Motor Algorithm Document
ucm software controls displays
UCM Software - Controls Displays
  • EDM display manager
    • edm 1-11-0s
    • Using templates provided by SLAC
ucm software smart monitors and test facilities
UCM Software - Smart Monitors and Test Facilities
  • Smart Monitors will mostly be sequence programs running in the IOC
    • No change in requested motor position even though it is “moving”
    • Loss of excitation voltage to potentiometers
    • Out-of-range RTD readings
    • BFW inserted
  • Test Facilities
    • Calibration and testing of translation stage “skew” interlock
ucm software access security
UCM Software - Access Security
  • Channel Access Security will be implemented during LTT development
  • Calibration parameters will be READ only
    • CAM rotary potentiometer gain and zero offset
    • CAM wedge angles
    • Linear potentiometer gain and zero offset
    • Girder fixed distance parameters
  • Machine operating mode restrictions
    • CAM calibration procedure prohibited during normal operations
    • BFW operation prohibited during normal operations
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