2nd collaboration meeting on X-band Accelerator Structure Design and Test-Program 

Structure fabrication

Test structure fabrication: procedures, documentation and status

G. Riddone

13.05.2008

Acknowledgements: C. Achard, S. Atieh, J. Kovermann, R. Zennaro, M. Taborelli

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Content

• Introduction • Production cycle• QA system• Status of the production• Conclusions

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Introduction

• Accelerating structures– 30 GHz (CERN): disks and quadrants– 11.4 GHz (CERN, KEK, SLAC): disks and

quadrants– 12 GHz (CERN): disks

• PETS– 30 GHz (CERN): quadrants– 11.4 GHz (SLAC): octants– 12 GHz (CERN): octants

• rf components (CERN)– Hybrids - Splitters– Loads– Directional couplers– Attenuators – Phase shifters– Flanges

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Production cycle for acc. structures

Production cycle: 24 weeks from RF design (included) to power test (excluded) Aim: 10 structures per year

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From rf design to the tech. specification

rf design: 4 weeksmechanical design: 4 weeksTech. Spec. + bidding: 6 weeks

3D Part, design parametrization introduced to minimize errors

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QA system

• We have to ensure that a physical components meet its requirements and perform satisfactorily in operation At any moment we should be able to trace the history of the components

Engineering Data Management System used at CERN  EDMS• for archiving and approval of documents• for information flow among different teams, including 

external suppliers/collaborators

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EDMS for RF structures

Traveller: document containing the history of the component

Daily notification mail with new documents

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Traveller (1)

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Traveller (2)

XX

X

X

X

X

X

X

X

X

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In addition:Logbook for each structure

It has been defined:- Who initiates the traveller - For each step, role and responsibility- Who closes the traveller and put it in EDMS

When a step is completed, the person in charge of the step, sends a mail to a defined list of people to launch the following step.After each step the structure is put back in its box and stored in the dedicated cupboard in b169

A new rf laboratory has been prepared for the structure inspection, assembly and tests

Traveller (3)

X

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Production Item  Firms 

Accelerating structures(8 weeks: allocated fabrication time)

Greenfox (FI), IMTEC (FI)VDL (NL), Micron-Cluny (FR)Megic (IT), Unitek (IT)Kugler (DE)

(KERN, LT Ultra-Precision under qualification) + collaborations with KEK and SLAC

PETS (14 weeks: allocated fabrication time) + couplers

IMP (IT), CINEL (IT), VDL (NL)G&P vacuum (SP), Unitek (IT)

rf components  CINEL (IT), VDL (NL)Gycom (RU)

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Ac. structure overview table (1)

VG1

C10

CLIC G

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Ac. structure overview table (2)

CLIC G

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Accelerating structures

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CLIC vg1 quadrant damped

Iris shape accuracy

- Specified: +/- 2.5 mm

- Obtained: - 5, +10 mm

No tuning needed

11.4 GHz

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Accelerating structures

Disk structure (technology resumed in 2007 following change of frequency)Machining by diamond turning (+milling for damped structures) specified shape accuracy of +/-1 mm in the iris region

30 GHz 11.4 GHz

150 mm

300 mm

Disk undamped

Disk damped

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PETS overview

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PETS production

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11.4 GHz

275 mm

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PETS production

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12 GHz

1 m

Cooling circuit assembly jig

Pieces for PETS assembly and supports

rf components

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Hybrids

GYCOM, RussiaFirst prototype in Dec 2007 - Series (x9) in June

RF and mechanical design, CERNFabrication in CINEL, Italy and VDL, Holland

Prototypes under completion - Series  (x8) at CERN in July  

Dry (stainless steel) RF load

Attenuator/phase shifter

Scaled from 30 GHz CERN version. GYCOM Russia.

First prototype in May - Second unit in Jul - Series  (x3) in AugRF and mechanical design, CERNFabrication in CINEL, ItalyFirst prototype in May  - Series (x4) in June

Directional couplers

Splitter order under way

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Conclusions

• A project-oriented production follow-up has been put into place a quality assurance system has been defined

• All the relevant documents available in EDMS: exchange of information within CERN and with external collaborators

• Detailed scheduled with clear milestones allow to follow the production and take preventive and correction actions

• Production cycle for accelerating structure takes approximately 6 months

• Several firms have been qualified for the manufacturing of the acc. structures, PETS and rf components. As much as possible splitting of contracts to minimize the risk. Collaboration with KEK And SLAC is a real benefit

• First accelerating structure at 11.4 GHz arrived last week. Preliminary rf results are promising. To be tested at SLAC.

• PETS bars and related components at 11.4 GHz under assembly and preparation.