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Measurement report of Boostec girders

Measurement report of Boostec girders. Measurements performed on the 28th of October 2010 with the Laser Tracker LTD500. Plan. INTRODUCTION Tolerances to be checked Coordinates system Summary 3079 girder 3069 girder CONCLUSION. INTRODUCTION.

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Measurement report of Boostec girders

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  1. Measurement report of Boostec girders Measurements performed on the 28th of October 2010 with the Laser Tracker LTD500

  2. Plan • INTRODUCTION • Tolerances to be checked • Coordinates system • Summary • 3079 girder • 3069 girder • CONCLUSION

  3. INTRODUCTION The objective of the measurements is to perform the dimensional control of the 2 Boostec girders on site before receipt at CERN. We measured this girders according to Nicolas Chritin plans and tolerances (EDMS n° 1098660) using the Laser Tracker Leica LTD500. Measurement conditions were good: temperature stability of 20.5°C to 20.8°C during the day. We will present measurement results with an accuracy of about 10 µm rms for the flatness and coaxialityand of about 20 µm rms for the positioning.

  4. Tolerances to be checked General tolerances of ± 0.01 mm, *Tolerances of ±  0.1 mm

  5. Tolerances to be checked

  6. Tolerances to be checked

  7. Coordinates system In a first time: _ Y axis = mean cylinders axis _ Z axis = perpendicular to the mean plan A _ System origin O = intersection of Y with the mean plan C However: _ The cylinder diameter is not exactly 120 mm long but 119.55 mm (LTD measurement) After checking of the V-supports geometry, the following coordinate system was chosen: _ Y axis = mean cylinders axis corrected by the offset of √2*Δφ/2, so 0.318 mm _ Z axis = perpendicular to the mean plan A _ System origin O = intersection of Y with the mean plan C

  8. Summary • 3079 girder • The only significant flatness faults for the 3079 girder are the following: • Definition of the upper plan D global: 15 µm rms. This fault has no impact because of the choice of the independent DBQ adjustment. • The local fault on the D plan on the girder centre: 49 µm rms, range of -210.247 mm to -209.882 mm. The concerning location is not essential to the DBQ adjustment.

  9. Summary • 3079 girder • Positioning fault: • The side plan F, B, H and I are not correctly located with respect to the median plan: offsets of the order of 0.15 mm whereas the tolerance is ± 10 µm. We propose that Boostec will machine the girder where there is too much material and for our part, we will define shims from CMM measurements to wedge where there is a lack of material.

  10. Summary • 3079 girder • The location of the D(entry) plan with respect to the beam axis is -209.914 mm instead of -210 mm. There is no impact because of the DBQ adjustment. • The distance between the lower plan A and the beam axis is too short of about 30 µm. The CMM measurement will permit to determinate with a better accuracy this fault and its impact. • No problem of perpendicularity.

  11. Summary • 3069 girder • The only significant flatness faults for the 3069 girder are the following: • Definition of the upper plan D global: 19 µm rms. Like for the first girder this fault has no impact. • The local fault on the D plan on the girder centre: 43 µm rms, range of -210.163 mm to -209.859 mm. The concerning location is not essential to the DBQ adjustment.

  12. Summary • 3069 girder • Positioning fault: • The side plan F, B, H and I are not correctly located with respect to the median plan: offsets of the order of 0.10 mm whereas the tolerance is ± 10 µm. In addition the girder is too narrow of approximately 50 µm. We propose the same solution as for the first girder : machining by Boostec and wedging by CERN. • The location of plans D, entry and exit, with respect to the beam axis are respectively -209.915 mm and -210.056m instead of -210 mm. There is no impact because of the DBQ adjustment. • No problem of perpendicularity.

  13. CONCLUSION According to the results and accuracy of LTD500, we can say that the Boostec girders don’t respect all the tolerances defined by Nicolas Chritin. The positioning faults seem to come from a mistake on the drawings instead of a lack of know-how However, following the «Dimensional control and fiducialisation » meeting of November the 9th, we think it will be possible to correct the faults if the girders are machined on the side plans. These corrections are possible because there are only two Boostec girders, but for the future of CLIC, when we speak of thousands of modules, it will be necessary to better translate our expectations into drawings.

  14. Supplementary Slide Flatness and coaxiality • 3079 girder • _ Plans flatness : • A : 9 µm rms • D (entry) : 9 µm rms • D (exit) : 10 µm rms • D global (entry + exit) : 15 µm • E : 2 µm rms • C : 7 µm rms • Bg : 5 µm rms • Bd : 5 µm rms • Fg : 9 µm rms • Fd : 2 µm rms • H : 8 µm rms • I : 4 µm rms • For all plans, the measurement flatness is of the order of the LTD accuracy, except for the D global plan. • In addition, there is a local fault on the D (entry) plan, located on the solder, at the center of the girder: flatness of 49 µm rms. • _ Axis coaxiality for the cylinder locations: 10 µm RMS

  15. Supplementary Slide Flatness and coaxiality • 3069 girder • _ Plans flatness : • A : 13 µm rms • D (entry) : 7 µm rms • D (exit) : 8 µm rms • D global (entry + exit) : 19 µm • E : 2 µm rms • C : 7 µm rms • Bg : 6 µm rms • Bd : 7 µm rms • Fg : 10 µm rms • Fd : 1 µm rms • H : 8 µm rms • I : 4 µm rms • For all plans, the measurement flatness is of the order of the LTD accuracy, except for the D global plan. • In addition, there is a local fault on the D (entry) plan, located on the solder, at the center of the girder: flatness of 43 µm rms. • _ Axis coaxiality for the cylinder locations: 10 µm RMS

  16. Positioning • 3079 girder • _ Positioning of C with respect to E (along Y), distance between mean plans : 1946.089 mm or 89 µm of offset with respect to the nominal length. • _ Positioning of A with respect to Y axis (along Z): distance from the mean plan A to the Y axis of 28.972 mm or an offset of 28 µm. • _ Positioning of Bgwith respect to the median plan: -64.823 mm instead of -65 mm • Positioning of Bdwith respect to the median plan:65.157 mm pour 65 mm • Positioning of Fgwith respect to the median plan: -64.856 instead of -65 mm • Positioning of Fdwith respect to the median plan: 65.130 mm instead of 65 mm • The girder width is good but the distances to the median plan are not respected. Supplementary Slide

  17. Supplementary Slide Positioning • 3079 girder • _ Positioning of D plans: • D(entry) without fault: -209.914 mm instead of -210 mm, or an offset of 86 µm. • D(entry), on the fault location, is located between a lower plan at -210.247 mm and an upper plan at -209.882 mm.  the fault does not exceed the girder. • D(exit): -210.008 mm instead of 210 mm • _ Positioning of H with respect to Y axis (along X): 65.154 mm instead of 65 mm • _ Positioning of I with respect to Y axis (along X): 65.153 instead of 65 mm • H and I are consistent with the Bd and Fd plans: there is an offset of +0.15 mm with respect to the median plan.

  18. Supplementary Slide Positioning • 3069 girder • _ Positioning of C with respect to E (along Y), distance between mean plans : 1946.075 mm or 75 µm of offset with respect to the nominal length. • _ Positioning of A with respect to Y axis (along Z): distance from the mean plan A to the Y axis of 528.982 mm, or an offset of 8 µm. • _ Positioning of Bgwith respect to the median plan: -65.04 mm instead of -65 mm • Positioning ofBdwith respect to the median plan: 64.906 mm instead of 65 mm • Positioning of Fgwith respect to the median plan: -65.088 mm instead of -65 mm • Positioning of Fdwith respect to the median plan: 64.865 mm instead of 65 mm • The girder is too narrow of approximately 50 µm and the distances to the median plan are not respected.

  19. Supplementary Slide Positioning • 3069 girder • _ Positioning of D plans: • D(entry) without fault: -209.915 mm instead of -210 mm, or an offset of 85 µm. • D(entry), on the fault location, is located between a lower plan at -210.163 mm and an upper plan at -209.859 mm.  the fault does not exceed the girder. • D(exit): -210.056 mm instead of -210 mm • _ Positioning of H with respect Y axis (along X): 64.898 mm • _ Positioning of I with respect to Y axis (along X): 64.891 mm • H and I are consistent with the Bd and Fd plans: there is an offset of -0.1 mm with respect to the median plan.

  20. Supplementary Slide Perpendicularity • 3079 girder • E with respect to A: offset of 10 µrad or 3 µm at 32 cm • C with respect to A: offset of -49 µrad or 16 µm at 32 cm • Bg with respect to A: offset of -346 µrad or 7 µm at 2 cm • Bd with respect to A: offset of 361 µrad or 7 µm at 2 cm • Fg with respect to A: offset of 227 µrad or 5 µm at 2 cm • Fd with respect to A: offset of 438 µrad or 9 µm at 2 cm • H with respect to D (exit): offset of 1203 µrad or 24 µm at 2 cm • I with respect to D (entry): offset of -438 µrad or 9 µm at 2 cm

  21. Supplementary Slide Perpendicularity • 3079 girder • Bg with respect to E: offset of -56 µrad or 3 µm at 5 cm • Bd with respect to E: offset of -89 µrad or 5 µm at 5 cm • Fg with respect to C: offset of -112 µrad or 6 µm at 5 cm • Fd with respect to C: offset of 24 µrad or 1 µm at 5 cm • C with respect to Y axis (around X): offset of -54 µrad or 17 µm at 32 cm • C with respect to Y axis (around Z): offset of -51 µrad or 7 µm at 13 cm • E with respect to Y axis (around X): offset of 19 µrad or 6 µm at 32 cm • E with respect to Y axis (around Z): offset of 14 µrad or 2 µm at 13 cm

  22. Supplementary Slide Perpendicularity • 3069 girder • E with respect to A: offset of -33 µrad or 11 µm at 32 cm • C with respect to A: offset of -5 µrad or 2 µm at 32 cm • Bg with respect to A: offset of -602 µrad or 12 µm at 2 cm • Bd with respect to A: offset of -335 µrad or 7 µm at 2 cm • Fg with respect to A: offset of 377 µrad or 8 µm at 2 cm • Fd with respect to A: offset of 473 µrad or 10 µm at 2 cm • H with respect to D (exit): offset of 24 µrad or 1 µm at 2 cm • I with respect to D (entry): offset of 679 µrad or 14 µm at 2 cm

  23. Supplementary Slide Perpendicularity • 3069 girder • Bg with respect to E: offset of 31 µrad or 2 µm at 5 cm • Bd with respect to E: offset of -61 µrad or 3 µm at 5 cm • Fg with respect to C : offset of -220 µrad or 11 µm at 5 cm • Fd with respect to C : offset of -23 µrad or 1 µm at 5 cm • C with respect to Y axis (around X) : offset of -57 µrad or 18 µm at 32 cm • C with respect to Y axis (around Z) : offset of -2 µrad or 0.3 µm at 13 cm • E with respect to Y axis (around X) : offset of 43 µrad or 14 µm at 32 cm • E with respect to Y axis (around Z) : offset of -35 µrad or 5 µm at 13 cm

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