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Metrology of DS11T

Salvador FERRADAS

11T TF Meeting #24 – 180 – 19 September, 2018

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Analysis of the metrology data of DS 11T #120

and #121 with a datum radius of 60.885

Salvador FERRADAS 2

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Aligning to a nominal OD of 60.885

Salvador FERRADAS 3

CS Z=650 Coil #120.1

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OD 60.8 OD 60.885

Salvador FERRADAS 4

Best fitted CS

CS Z=650 Coil #120.1

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Results

Salvador FERRADAS 5

-0.15

-0.1

-0.05

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0 200 400 600 800 1000 1200 1400 1600

Dev

iati

on

to

no

min

al [

mm

]

Position (straight section) [mm]

Coil azimuthal size

120

121.1 60.885

121

120.1 60.885

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Average left&right shimmed quadrant excess

Salvador FERRADAS 6

0.000

0.100

0.200

0.300

0.400

0.500

0 200 400 600 800 1000 1200 1400

Mid

pla

ne E

xcess [m

m]

Position (straight section) [mm]

Assembly excess

OD 60.80 Average left/right w shim per quadrant

OD 60.885 Average left/right w shim per quadrant

120 µm

211 µm

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Measurement of the thickness of the teflon-

coated impregnation shims*.

Salvador FERRADAS 7

*Both 2 shims used indistinctively

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TESA ISOMASTER1

Vernier scale

(resolution): 0.01mm

Accuracy: 0.01mm?

Friction coupling for

consistent, repeatable

measuring force

Rounded probe to

measure

perpendicularly to the

surface (8mm

diameter).

Salvador FERRADAS 81

http://media.witglobal.net/stmedia/hahnkolb/documents/LANG_en/HK-31366225.pdf

Note an offset of around//less than 10 micron. The tooling

was not found to reset the 0 Vernier scale…

Measurement of the thickness of the Teflon

coated impregnated shim

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The shim of ~2150mm was measured

each 100mm. Two points were probed

for each cross section, one at each

side of the shim. As deep in the arc as

possible.

The true value was considered the

smallest measured.

Salvador FERRADAS 9

Measurement of the thickness of the Teflon

coated impregnated shim

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The blank of stainless steel of which the

shims were formed was also measured.

Thickness between 0.470 and 0.480

mark using TESA ISOMASTER rounded

probe (remember 10 micron offset and

resolution).

Thickness = 0.483 using TESA flat probe

(1 micron resolution).

Excellent repeatability. Stdev:0.00046

Stderror: 0.00015

Salvador FERRADAS 10

Measurement of the thickness of the Teflon

coated impregnated shim No offset. Perfectly aligned at 0

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Measurement of the thickness of the Teflon

coated impregnated shim

0.47

0.48

0.49

0.5

0.51

0.52

0.53

0.54

0.55

0.56

0.57

0.58

0.59

0.6

0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200

Thic

kne

ss [

mm

]

Position [mm]

SHIM 1

SHIM 2

TARGET

BLANK

NOMINAL CAVITY SIZE

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Measured cavity OD

NominalImpregnation

Tool 1

Impregnation

Tool 2

IR of impregnation blocks, mm 61.425 61.355 61.435

Stainless steel shim, mm 0.5 0.475 0.475

Coating or demolding agent, mm 0.1 0.03 0.03

Tolerance, mm 0.025 0 0

OD impregnated coil 60.80 60.85 60.93

Remark: all these measurements have error bars…careful when

looking at micros!

• Coils impregnated in tool 1: 101-107, 110

• Coils impregnated in tool 2: 108-109,111-123

Thanks to Susana Izquierdo 18.09.2018

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A few words about the metrology of the

impregnation moulds @ 927.

Credits to C. Hannes Loffler

13

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Tool 1 Tool 2Visible error come from the

horizontal alignment of the

tool blocks on the tableChristian H. Loffler 27.01.2015

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Block cavity diameter

-0.12

-0.1

-0.08

-0.06

-0.04

-0.02

0

0.02

0.04

1 11 21

cavi

ty d

ia. [

mm

]

# block

tool 1 cavity dia.

tool 2 cavity dia.

Size of the cavity

diameter. Each

block measured

individually, no

global alignment

used.

Nominal R:

61.425 mm Avg dev: +0.0104 mm

Max: 0.027 mm @ 8

Min: -0.004 @13

Christian H. Loffler 27.01.2015

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Analysis of the metrology data of the coils to

be used in SP108 & SP102b

Salvador FERRADAS 16

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SP108

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0 500 1000 1500

Mid

pla

ne

Exce

ss [

mm

]

Position (straight section)

Coil #119

Coil Midplane Right Coil Midplane Left Total excess

119 123

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0 500 1000 1500

Mid

pla

ne

Exce

ss [

mm

]

Position (straight section)

Coil #123

Coil Midplane Right Coil Midplane Left Total excess

Avg: 215 µm

Max: 387 µm

Min: 129 µm

Avg: 531 µm

Max: 736 µm

Min: 305 µm

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•Right•Left

119 L

119 R

123 L

123 R

SP108

-0.2

-0.1

0

0.1

0.2

0.3

0.4

0.5

0.6

0 200 400 600 800 1000 1200 1400

Mid

pla

ne

Exce

ss [

mm

]

Position (straight section)

Left & Right Coils excess

Right

Left

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0.000

0.050

0.100

0.150

0.200

0.250

0.300

0.350

0.400

0.450

0.500

0 200 400 600 800 1000 1200 1400

Exce

ss [

mm

]

Position (straight section)

Assembly excess

Salvador FERRADAS 19

•Right•Left

119 L

119 R

123 L

123 R

SP108 – 0 pole shim left & right + (0.125

polyamide + 0.15 316L, Top shim = 0.2)

187 µm

102 µm

281 µm

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0.000

0.050

0.100

0.150

0.200

0.250

0.300

0.350

0.400

0.450

0.500

0 200 400 600 800 1000 1200 1400

Exce

ss [

mm

]

Position (straight section)

Assembly excess

Salvador FERRADAS 20

•Right•Left

119 L

119 R

123 L

123 R

SP108 – 0.05 pole shim left & right @ Z≤350 & Z≥980 +

(0.125 polyamide + 0.15 316L, Top shim = 0.2)

220 µm

152 µm

281 µm

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Analysis of the metrology data of the coils to

be used in SP102b

Salvador FERRADAS 21

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-0.15

-0.05

0.05

0.15

0.25

0.35

0.45

0 500 1000 1500

Mid

pla

ne

Exce

ss [

mm

]

Position (straight section)

Coil #106

Coil Midplane Right Coil Midplane Left Total excess

Salvador FERRADAS 22

SP102b

106 108

Avg: 186 µm

Max: 393 µm

Min: 107 µm

-0.15

-0.05

0.05

0.15

0.25

0.35

0.45

0 500 1000 1500

Mid

pla

ne

Exce

ss [

mm

]

Position (straight section)

Coil #123

Coil Midplane Right Coil Midplane Left Total excess

Avg: -20 µm

Max: 75 µm

Min: -116 µm

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•Right•Left

106 L

106 R

108 L

108 R

SP102b

-0.2

-0.1

0

0.1

0.2

0.3

0.4

0.5

0.6

0 200 400 600 800 1000 1200 1400

Mid

pla

ne

Exce

ss [

mm

]

Position (straight section)

Left & Right Coils excess

Right

Left

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•Right•Left

106 L

106 R

108 L

108 R

SP102b – 0.2 pole shim left & right + (0.125

polyamide + 0.15 316L, Top shim = 0.2)

0.000

0.100

0.200

0.300

0.400

0.500

0 200 400 600 800 1000 1200 1400

Exce

ss [

mm

]

Position (straight section)

Assembly excess

241 µm

179 µm

279 µm

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Thanks for your attention

Salvador FERRADAS 25