Undulator for the LCLS project – from the prototype to the full scale manufacturing

1. Undulator for the LCLS project – from the prototype to the full scale manufacturing LCLS Undulator Final Design Review

2. OUTLINE • Major Design features • Latest Design Changes (Internal ANL Review - June 18, 2004 ) • Long Lead Items • Manufacturing Approach LCLS Undulator Final Design Review

3. PARTIAL LIST of LCLS UNDULATOR REVIEW 2003 Lehman Review (May 21-23, 2003) - Rockville, MD LCLS Undulator Parameter Workshop - ANL - October 24, 2003 Review of the LCLC Undulator - ANL - November 14, 2003 LCLS Undulator Diagnostics and Commissioning Workshop - UCLA - January 19-20, 2004 LCLS Undulator System Review - ANL - March 3-4, 2004 Internal ANL Review - June 18, 2004 External Independent Review - SLAC - June 7-11, 2004 LCLS Undulator Physics and Engineering Meeting - ANL - June 28-29, 2004 LCLS Undulator Meeting - ANL - July 23, 2004 Lehman Review at SLAC - August 10-12, 2004 LCLS Undulator Final Design Review

4. LCLS – general view LCLS Undulator Final Design Review

5. LCLS prototype undulator on the magnet measuring stand LCLS Undulator Final Design Review

6. LCLS Prototype Undulator (major design features ) 1.Titanium housing made of forged 12” bar. 2. Base of the magnet structure sections made of aluminum alloy to partially compensate the changes in the magnetization of the permanent magnets with temperature. 3. Only one clamp for each magnet is made of bronze. 4. Incremental shims or might be used for the undulator gap adjustment. 5. Out-bond area is completely open for the side shims to tune the field strength along the undulator. 6. Side shims have four bars made of low carbon steel. Each bar can be individually adjusted and locked in place. 7. Five cam-shaft movers are used for alignment of the undulator as a whole. LCLS Undulator Final Design Review

7. LCLS Undulator Latest Design Changes 1. Canted undulator design (wedged shims) – proposed by Joachim Pflueger 2. Housing has provision for “magnetic needles” and alignment targets. 2. Simple pole design with two clamping screws from the bottom. 3. Outside fixture for the pole installation. 4. New side shim design to decrease fringed field. 5. New cam-shaft mover deisgn. 6. Magnet structure base made as a single block (three parts before) LCLS Undulator Final Design Review

8. LCLS undulator with wedged shims (canted) LCLS Undulator Final Design Review

9. LCLS prototype undulator magnetic structure with two pole clamps LCLS Undulator Final Design Review

10. LCLS magnetic structure (old and new) Implementation of the new design can save about $20K - $25K per undulator LCLS Undulator Final Design Review

11. LCLS magnetic structure base – new design Implementation of this new design can save about $4K - $5K per undulator LCLS Undulator Final Design Review

12. LCLS magnetic structure with a single unit base LCLS Undulator Final Design Review

13. LCLS undulator pole assembly fixture LCLS Undulator Final Design Review

14. Fixture for the Magnet Structure Assembly LCLS Undulator Final Design Review

15. LCLS Prototype Undulator Titanium Housing LCLS Undulator Final Design Review

16. LCLS Prototype Undulator magnetic needle test set-up LCLS Undulator Final Design Review

17. LCLS Undulator Housing Design Changes Manufacturing simplification 1. Counterbore clamping holes instead of counterbore groves. 2. No provisions for phase shifters. 3. Central grove for vacuum chamber location is removed. 4. More simple provisions for the support pads. Improvements for more precise alignment 1. Housing has provision for “magnetic needles” on both ends. 2. Housing has provisions for four sets of alignment targets. LCLS Undulator Final Design Review

18. LCLS Undulator Pole Material: VACOFLUX 50 (vanadium permendure) Quantity: PER UNDULATOR - 450 TOTAL - 19200 TOTAL WEIGHT: ~ 5300 lbs LCLS Undulator Final Design Review

19. LCLS Undulator Magnet Material: N39UH (Nd-Fe-B type magnet ) Quantity: PER UNDULATOR - 450 TOTAL - 19200 TOTAL WEIGHT: ~ 10900 lbs LCLS Undulator Final Design Review

20. Manufacturing approach • Design of the undulator itself is ready for manufacturing, • Design of the undulator support cradle and all associated motions is 2005 year task. Nevertheless we can’t see its impact on housing design. Some minor changes in the support area location can be easily corrected during the manufacturing – we have time; • It is not necessary to work with only companies, who have undulator experience, our choice of vendors is quite wide; • We are going to teach and train selected vendor (vendors) how to assemble magnetic structure of LCLS undulator and how to put it inside housing. Detailed procedure is written and necessary fixtures are designed. LCLS Undulator Final Design Review

21. Conclusion • Prototype of the LCLS undulator was successfully designed, manufactured, tuned, and tested; • Multiple changes in the design of the prototype were implemented, tested in the preparation for the full scale production, and approved by internal design review ; • Forty undulators will be manufactured in the next three years; • Procurement package for the long lead items (strong back, magnets and poles) is 98% ready; • We would like to have one LCLS undulator each two weeks. LCLS Undulator Final Design Review