midterm review 28-29/05/2015 iordan doytchinov esr3.1, wp3 1
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Midterm Review 28-29/05/2015
Iordan DoytchinovESR3.1, WP3
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ESR3.1, WP3 /
Contract start date: 3rd March 2014
PACMAN subject: Ultra-precise quadrupole magnet assembly and testing. Integration of an alignment test-bed towards an industrial production
PhD title: Measurement uncertainty budget for future particle accelerators alignment bench
PhD Institution: Cranfield University
Secondment: DMP Spain (3M)
Iordan DOYTCHINOV, ESR3.1PACMAN Mid-term review 28-29/05/2015
CERN Supervisor Michele Modena
Academic supervisors Dr. Paul Comley, Prof. Paul SHORE
Industry supervisor Jorge Presa
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Background /
Test automation - 1 year
Vehicle Dynamics/ Performance - 3 months
Omron ltd Barcelona:Real-Time robot dynamics simulation (Master THESIS)UAV Performance Estimation
/system Integration
I come from here - Sofia - BULGARIA
Beside Engineering…
Iordan DOYTCHINOV, ESR3.1PACMAN Mid-term review 28-29/05/2015
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PhD thesis /
Title: Measurement uncertainty budget for future particle accelerators alignment bench
Start date: 05.2014
Status: 1st year critical (GO/NO-GO) review passed
Note: Precision engineering training done at the university.
Iordan DOYTCHINOV, ESR3.1PACMAN Mid-term review 28-29/05/2015
Project /
Place in PACMAN
Iordan DOYTCHINOV, ESR3.1PACMAN Mid-term review 28-29/05/2015
Ultra-precise quadrupole magnets assembly and testing
Uncertainty budget for PACMAN and thus:
• Work contributed to PhD hypothesis formulation but not selected as one.
• research plan reformulated to follow closely PhD hypothesis
Bench System Integration – evaluation of system requirements and bottleneck problems
A) Defining its measurement capability.
B) Development of calibration and error compensation procedures for the system.
C) Proving if the concept can be scaled up for mass production.
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Project /
Objectives
Iordan DOYTCHINOV, ESR3.1PACMAN Mid-term review 28-29/05/2015
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I) Define error sources contributing to the measurement uncertainty (current work)
JCGM 100:2008
P.R. Guimarães Couto1 et all (2013)
II) Allocate the level of measurement uncertainty for each critical error source
III) Construction of final integrated system uncertainty budget.
Prove or disprove if targeted measurement uncertainty is achievable:• 7 µm (BPM axis)
• 11 µm (Magnet axis)
Future work
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Project/
BPM
State of art
predicted expected error budget for this type of measurement.
Fig 22: Stretched wire setup measuring quadruple magnet [23]
Wire stretching bed by 2x spheres
Wire stretching bed by 2x spheres
> 20µm @ U(68%)
𝑈𝑝𝑟𝑒
−𝑎𝑙𝑖𝑔𝑛𝑚
𝑒𝑛𝑡
𝑈=√∑ 𝜎 2
Iordan DOYTCHINOV, ESR3.1PACMAN Mid-term review 28-29/05/2015
State of the art
Project/
Iordan DOYTCHINOV, ESR3.1PACMAN Mid-term review 28-29/05/2015 8
Magnetic axis definition
Wire axis non- contact definition
within CMM
Tactile datum measurement
No in-depth uncertainty analysisNo common terminology or method applied Integrated uncertainty budget does not exist
GAP OF KNOWLEDGE:
Wire
Sensor
𝑼 𝟐
BPM axis definition
Research Gap
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Project /
Method followed
Iordan DOYTCHINOV, ESR3.1PACMAN Mid-term review 28-29/05/2015
II) Literature review
I) QFD analysis, CAD studies , communication with sub system owners (PACMAN students)- System integration, definition of error sources
𝐔𝐩Measurement
ProcessUncertainty
budget
Changeassumptions
Task
- Standards (GUM, ISO)- Error budgets on complex
systems
III) Experiments design
- Evaluation of magnitude, sensitivity and correlation of uncertainty contributors in 4x work packages
Measurements
Electromagnetic
Task Specific Uncertainties
Sub System Uncertainties
Task specific uncertainties
BPM RF Axis Measurement
Magnetic Axis Measurement
Measurements
Electromagnetic
Task Specific Uncertainties
Sub System Uncertainties
Task specific uncertainties
BPM RF Axis Measurement
Magnetic Axis MeasurementMagnetic axis
measurement package
Measurements
Electromagnetic
Task Specific Uncertainties
Task specific uncertaintiesSub System Uncertainties
Task specific uncertainties
BPM RF Axis Measurement
Sub System Uncertainties
Electromagnetic
Thermal Issues BPM
Geometrical Issues
Vibration Issues
Measurements
Electromagnetic
Task Specific Uncertainties
Task specific uncertaintiesSub System Uncertainties
Task specific uncertainties
BPM RF Axis Measurement
Sub System Uncertainties
Electromagnetic
Thermal Issues BPM
Geometrical Issues
Vibration Issues
BPM electric axis measurement
package
Measurements
Electromagnetic
Task Specific Uncertainties
Sub System Uncertainties
Task specific uncertainties
Wire Location Measurement
Measurements
Electromagnetic
Task Specific Uncertainties
Sub System Uncertainties
Task specific uncertainties
Wire Location MeasurementWire axis location
measurement package
Measurements
Electromagnetic
Task Specific Uncertainties
Sub System Uncertainties
Task specific uncertainties
Global Zero Datum measurment - CMM Measurements of Sphere fiducials
Wire Location Measurement
Measurements
Electromagnetic
Task Specific Uncertainties
Sub System Uncertainties
Task specific uncertainties
Global Zero Datum measurment - CMM Measurements of Sphere fiducials
Wire Location Measurement
CMM task specific measurement uncertainty
evaluation package𝑼 𝟏
𝑼 𝟐
𝑼 𝟑𝑼 𝟒
Project /
Tasks description
Iordan DOYTCHINOV, ESR3.1PACMAN Mid-term review 28-29/05/2015
9 months GO/ NO-GO 30th of April
DMP secondment 06.2015 – 09.2015
Magnetic axis definition uncertainty budget
evaluation02.2016
Zero datum uncertainty budget
evaluation11.2015
Electric axis definition
uncertainty budget evaluation
05.2016
Non-contact uncertainty budget
evaluation07.2016
2nd Year GO/NO-GO 04.2016
PACMAN integrated system U evaluation package
11.2016
Thesis preparation 03.2017
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Results
Iordan DOYTCHINOV, ESR3.1PACMAN Mid-term review 28-29/05/2015
Assembly not trivial – errors correlate: Magnetic axis measurement to be included in the magnet assembly loop?
Practical assembly studies of quadruple magnet investigating existing methods
Literature review on the subject Assembly trials completed:Results:
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Relationship Matrix
Quality Function Deployment initial analysis done:
Results
Iordan DOYTCHINOV, ESR3.1PACMAN Mid-term review 28-29/05/2015
Project /
Metrology loop interferenceNo access for non-contact sensor A) Re-design
B) Change of strategy
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Uncertainty analysis
Results
Iordan DOYTCHINOV, ESR3.1PACMAN Mid-term review 28-29/05/2015
MeasurementsUncertainty Components
Electromagnetic
Task Specific Uncertainties
Task specific uncertaintiesSub System Uncertainties
Task specific uncertainties
Vibration Issues
Global Zero Datum measurment - CMM Measurements of Sphere fiducials
Thermal Issues
Geometrical issues
Vibration Issues
Task specific uncertainties
Sub-Systems Uncertainties
BPM RF Axis Measurement
Sub System Uncertainties
Electromagnetic
Thermal Issues BPM
Geometrical Issues
Vibration Issues
Wire Location Measurement
Magnetic Axis Measurement
Thermal Issues
Vibration Issues
Geometrical Issues
Electromagnetic
Electromagnetic
Thermal Issues
Geometrical issues Quantify ΔT for current thermal control state of art
How ΔT of magnet propagates to magnetic axis
measurement?Udt= ΔT x α x L?
𝑼𝒎𝒂𝒈𝒏𝒆𝒕𝒊𝒄
𝑼 𝒆𝒍𝒆𝒄𝒕𝒓𝒊𝒄
Magnetic axis measurement
BPM electric axis
measurement
Wire axis location measurement
Zero datum measurement
(CMM)
MeasurementsUncertainty Components
Uncertainty Components Detail
Optical sensor measurment uncertaintyTension extrapolation error (wire sag correction)
Wire typeElectromagnetic External Electromagnetic Influence
Magnet HeatingEnviroment
Wire stretcher actuators and electronics thermal influence
Magnet cooling vibration influence @ Wire stretcher and Manget
Coultural noise through MBQ fraimeResolution of wire positioning in space
Perpendiculiarity of movement of axis stagesLocation magnet centre VS wire centre
Task Specific UncertaintiesTwo measurments to determine axis required
Other to be determined
Sub-Systems Uncertainties
Magnetic Axis Measurement
Thermal Issues
Vibration Issues
Geometrical Issues
ΔT ?𝑈 𝑥
Time
T
ΔT
dt
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Training
Iordan DOYTCHINOV, ESR3.1PACMAN Mid-term review 28-29/05/2015
Secondment in DMP – Spain(06.2015-10.2015):
“Analysis of error budget and uncertainties of robotic mechanisms for measuring the spine movement during transpedicular approach surgery” Opportunity to practice kinematics mechanism error
propagation budgeting Opportunity to spent time in precision engineering company:
Introduced to internal standards and procedures on metrology and manufacturing.
Precision engineering training in Cranfield University 1 week (11 principles of precision design)
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Training /
Iordan DOYTCHINOV, ESR3.1PACMAN Mid-term review 28-29/05/2015
Training (at CERN) on metrology and alignment- 3 day ISO GD&T course- 2 day general metrology- 1 week spent as apprentice in metrology
laboratory
Training (at CERN) on CATIA software – 2 weeks
Training (at CERN) on ANSYS software – 1 week
“Teambuilding” development course (1day)
Presentation making development course (3days)
Language course – basic level French
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Conferences & workshop:
Participation to EUSPEN 2014 Meeting on Thermal Issues
Participation and presenting in PACMAN workshop
CONTROL fair Stuttgart (discussed and shared PACMAN project with industry)Outreach &Dissemination /
Iordan DOYTCHINOV, ESR3.1PACMAN Mid-term review 28-29/05/2015
Other: CERN guides training
At CERN
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Networking Opportunities /
Iordan DOYTCHINOV, ESR3.1PACMAN Mid-term review 28-29/05/2015
Visit at KOTEM technologies in Budapest
Organised a visit and presentations of KOTEM and SIGMETRIX tolerance analysis software companies at CERN
CONTROL fair Stuttgart
PACMAN workshop
Discussions and online meetings with PhD students from Brazilian Synchrotron Light Source working on similar project
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Impact
Iordan DOYTCHINOV, ESR3.1PACMAN Mid-term review 28-29/05/2015
Contribution to DMP research project error and uncertainty analysis for medical purposes (DMP)
Personal
Dissolution my borders
Made me believe
Professional
Contribution to system integration required for PACMAN project (CERN)
Contribution to state of art in uncertainty analysis in accelerator components pre-alignment (CERN)
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Midterm Review 28-29/05/2015
Thank you for your attention
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