evolving mechanical technology for high energy accelerator

加速器だから見える世界。

Evolving Mechanical Technology for High Energy Accelerator Science

November 9, 2021

Mechanical Engineering Center(MEC)

Kenji Ueno

1971 Completion of

the first work building

1982～ Mechanical Engineering Center


１．History of Mechanical Engineering Center（MEC）２．From the initial support work of Mechanical Engineering Center（MEC）３．Engineering that supports High Energy Accelerator Science

＊Belle experiment (SVD, QCS)＊TIG automatic welding technology for J-PARC neutrino beamline＊CAD, 3D engineering for MLF neutron beamline＊To, Fermi Chopper development for MLF neutron beamline＊Robot automatic transfer technology for PF beamline＊Construction of Cavity Electropolishing（EP) Facility＊Cavity Fabrication Facility（CFF) construction ＊Cavity fabrication technology development＊X-band structure manufacturing technology development＊Precision measurement without a reference plane

４．Basic research for next-generation of Mechanical Engineering Center(MEC)

５．Summary Reference

Contents


Established common research work department, 1st work building completedDepartment Manager Hongo

Manufacture of hydrogen bubble chamber experimental equipmentBending magnet manufacturing, Superconducting electromagnet coil winding jig manufacturingCompletion of radioactive processing building,Manufacturing of septum magnet, manufacturing of Cherenkov counterCompletion of 2nd and 3rd work buildings,Manufacturing of superconducting 2-pole magnets for TRISTANManufacturing of mirror surface shape measuring device for PFAMY Drift Chamber (CDC)for 32,000 Holes (’85) WiringEstablished a work center Head KojimaResearch on ultra-precision machining and diffusion bonding for x-band structure Head KoizumiManufacturing of 14m superconducting 2-pole magnet, Trial production of 30cm X-band structure by interfacial bonding

１９７１

１９７３１９７４

１９７７

１９８２

１９８３１９８４１９８８１９９０

１９９３

１．History of Mechanical Engineering Center（MEC）（１）

Mission of MECDevelopment, research, design and manufacture of high-energy particle accelerators and devices used for various experiments,And research and development of precision processing technology.

Fiscal year Main events


Common Research Facility Work Center Head HitomiDevelopment of brazing technology using a hydrogen furnace,Manufacturing of KEKB measuring instrument SVD-IIManufacturing of X-band 60 cm structure Head UenoRenamed to Mechanical Engineering Center, Applied Research LaboratoryConstruction of cavity electropolishing(EP) facility, ('08) Start of operation of EP facilityConstruction of Cavity Fabrication Facility (CFF)ILC standard cavity production Head YamanakaDevelopment of automatic sample exchange system by robotManufacturing of flux concentrator headHigh-precision form measurement of large objects using a gyro

Head MonjyushiroMuon g-2 / EDM experimental position tracking detector prototype developmentCavity manufacturing for basic experiments Head Hiraki

１９９７２００１

２００３２００４２００７

２０１１２０１２２０１４２０１５２０１８

２０１９

２０２０

Fiscal year

From the support work to research work

Challenge and creation to the limit: ultra-precision, ultra-low temperature, ultra-high vacuum, high cleanliness, ultra-high speedEquipment requirements: safety, stability (repeatability), ease of operation / operation

１．History of Mechanical Engineering Center（MEC）（２）

Main events


Structure welding

Winding work for large coils Experimental equipment parts manufacturing

AMY driftchamber wiring(1985）

２．From the initial support work of the mechanical engineering center

Tig welding

Cherenkov counter manufacturing (1978)

Manufacture of 500MHz superconducting cavity (1981)

Drilling 32,000end plates for AMY

(1984)


Researchers in

accelerator science

Science Technology

Engineers

（Design engineers)

Specifications,

Drawings &

Information

Coexistence and

co-prosperity

Focus on １ｓｔＲ＆Ｄ、second and

subsequent units

Focus on drawing and

documentation

1st R & D

Common points:

Running at the top of the world, becoming a base, participating in international projects

Becoming a source of the latest technology, elemental technology

development, and technology transfer

Research and

Development

３．Engineering that supports High Energy Accelerator Science(Draft)

Manufacturing


Collision point measuring device

１ｍ

Aluminum alloy (A5083)Young's modulus 70 GPaCFRP (Dialed + Resin)Young's modulus 240 / 160GPa

Completion of SVD Manufacturing of Ladder Assembly

Support at both ends, deformation

due to own weight:~ 20 μm or less

Ladder deformation: 10 μm or lessBelle detector (about 1000 tons)

Computer calculation diagram

3.1 Belle experiment (Silicon Vertices Detector Development


2021/11/9 50周年記念 8

SuperKEKB R&D Magnets for

Nano-beam collision (2010-2013)TRISTAN QCS (1990-1995)

QCS :Quadrupole magnet for Collision in Superconductivity

Courtesy of Ohuchi

Under construction of Super KEKB Nano-beam collision area(2010-2013)

Superconducting magnet near the collision point

SuperKEKB R&D

Magnets (2004-2012)

Length 1.4m QC1P/QC1E prototype magnets

3.2 Belle experiment (QCS Development)（１）

加速器だから見える世界。Machining by CNC

machining center

Tool root check by CAD

Winding work

Fixing work of spacer and

superconducting wireMiniaturized QCS

Joint research with

Cryogenic Science CenterSpacer processing and coil manufacturing

3.2 Belle experiment (QCS Development)（２）

1st R&D quadrupole magnet

6-layer-superconducting quadrupole magnet (2004-2006)

SuperKEKB R&D Magnets for

Nano-beam collision (2010-2013)


10

Cryostat being installed

Automatic welding of long shaft pipe (shell)

Weld only from the outside

welding

Pass the welding standards of High Pressure Gas Safety Law

Confirmed the operating performance of the automatic welding machine

（Machine settings, Groove shape, Groove management, Insert ring,

welding current, etc. )

Neutrino Beamline Superconducting

Magnet System

Welding technology transferred to manufacturing

contract company with work procedure manual

By Yasuo Ajima

A shell made by bending a

stainless steel plate with a

thickness of 10 mm

Pressure vessel

holding refrigerant

The pressure vessel

goes inside this tube

Automatic welding machine

Insert ring

Numbers is

the number

of welding

passes3.7m

Weld point

3.3 TIG automatic welding technology for J-PARC neutrino beamline

Joint research with

Cryogenic Science Center


11

Large vacuum chamber scattered particle detector

HRC beamline

Design, calculation & installation work study using computer

Strength calculation

of thin AL window

High Resolution Chopper

Spectrometer (HRC)

On 3DCAD,space, weight, interference confirmation,

installation method, maintenance examination of shield High Resolution Chopper Spectrometer (HRC)

４ｍ

Large vacuum chamber

3.4 CAD, 3D engineering for MLF neutron beamline

5m


12

Ultra-high-speed, high-precision rotation-controlled chopper

Rotation accuracy:

T0 chopper 6000 rpm Fermi Chopper 36000 rpm

中性子ビー

ムNeutron

pulse

beam

Achievement ６００Hz±０．００１Hz

Error 0.02 mm at speed 125 m / sec

Neutron

pulse

beam

Error 0.5 mm at speed 94 m / sec

BL12,BL21,BL22,BL23：Total 5sets BL12(HRC)：2sets


Spectrometer (HRC)

Rotor Weight :120kgMaterial : InconelX750

3.5 To, Fermi Chopper development for MLF neutron beamline （１）

加速器だから見える世界。13

t=w/2Rf

w=80mm, w=1mm,

R=300mm, f=100Hz

t=5s: control accuracy

R=300mm

T0 chopper

High speed type (100Hz)BL04, installed in 2008BL12, installed in 2010

Frequency: 100Hz

Required control accuracy: ±5s

Accumulated running time: 4648h > 4000h

Continuous running time: 1551h > 1000h

Motor: AC servo, 10kW, 50Hz, air-cooled

Rotor: Inconel X750, 120kg, 4.7kgm2,

L=300mm, in vacuum (~1Pa)

Bearings: water-cooled ball bearings

1

0

nu

mb

er

of

ev

en

ts

-5 0 5

deviation from target timing (s)

ON OFF

Phase control circuit

1s

off-beam

experiment


Spectrometer (HRC)

Semi-auto installation mechanism

for air & water

Semi-automatic installation guide

Electrical system

Realization of stable operation for a long time> 4000h

3.5 To, Fermi Chopper development for MLF neutron beamline （２）

加速器だから見える世界。14

Slit

Mag. bearingControl circuit

Motor

Rotor pulse

ACC

Mag. bearing

Motor

Rotor pulse

ＤＤＳf=0.012Hzfmax=600Ｈｚ

202.5

202.0

201.5

201.0

200.5

frequ

enc

y (H

z)

1.0841.0821.080

voltage (V)f=1Hz

ACCf = 1/tf = |df/dt| t = f2t

t = 0.7s x 0.3 = 0.2s

f = 0.2Hz (f=1kHz)= 0.07Hz (f=600Hz)

Analog input 0-5V:100-600Hz

Development of Fermi chopper controller

Digital inputDirect Digital Synthesis

n=120f/p

n:Number of speed(rpm)

ｐ：Number of pole

f : Frequency of E. power

Improvement of turbo molecular pump（TMP)

TMP

Fermi chopper

TMPcontroller

TMPcontroller

Control circuit

Slit


Spectrometer (HRC)

3.5 To, Fermi Chopper development for MLF neutron beamline （３）


15

Force Sensor 4-axis Robot

Goniometer head

96x3=288pins

Calibration

Detection of collisions

Cryo Tongs=Robot hands

2D barcode reader

PAM : PF Automated Mounter

Application to complex movements of industrial robots PAM BL-5A

3.6 Robot automatic transfer technology for PF beamline

Liquid N2 Dewar

Cassette of

cryo-pins


EP HPR Assembly

In Clean room

(Class 10)

Flange-CP

Baking

(Class 1000)Hanging

StandVertical Test

Inspection of

Inner Surface

Rinsing

H2O2

Hot bath

(Alcohol)

(Degreasing)

Pre-tuning

of adjustment

Courtesy of STF Cavity G

Mechanical Engineering

Center Responsible Part

Vacuum furnace heat

treatment (Off line)

Cavities manufacuterd at KEK: KEKB, Club, ERL, ILC, Single cavity

Cavity production and cavity electropolishing in KEK Tsukuba campus

3.7 Construction of Cavity Electropolishing(EP) Facility （１）

加速器だから見える世界。EP liquid reserve tank installed on

the ground floor

EP acid: 1200ℓ

For ILC specialization, 9-cell

cavity, single-cell cavity

Amount of polishing per cell when polishing 20 μm

First EP processing resultーー--- A value of 27.3 MV / m in the

electric field was obtained.

EP equipment layout

Stable electrolytic polishing process and assembly

work in a clean room

Clean room（Class 10）

EP area Exhaust gas treatment equipment

Conceptual drawing when working on the electrolytic polishing bed

Joint work with

Chemical Center3.7 Construction of Cavity Electropolishing(EP) Facility （２）

加速器だから見える世界。 18

Superconducting cavity

manufacturing process

Condition: 18,000 / 5 years

6,000 / Asia area

Goal: 6 bottles / day

Maintaining vacuum, strength, high electric field

performance, and passing high pressure gas regulations

Total length 1247.6 mm

Large diameter φ206.85 mm

Courtesy of Kako

1.3GHz, L band

Establishment of electron beam welding (EBW) technology

3.8 Cavity Fabrication Facility (CFF) construction （１）


Clean room 19m x 14m, 5m Height

Cleanliness ISO 5

Grand opening ceremony July 13, 2011Completed clean room

Press processServo press machineEBW machine

Aiming to be a base for ILC cavity production

3.8 Cavity Fabrication Facility (CFF) construction （２）Joint work with

Accelerator Groupe


EBW processing

Example of temperature

calculation during EBW ANSYS

Completed (Before wearing the jacket)

Old model EBW

After this process →EP processing,……

0mm

0.5mm

Nb

Material

Ti

Welding joint

1mmEBW power 0.9kw,

Beam dia. 3mm,

Moving speed 5mm/sec,

Giving heat on the Ti / Nb

surface and simulated the

temperature distribution. (Plot

after welding length of 20mm)EBW of equator area

1.5mm

offset

Nb Ti

Offset1.5mm

Beam center

Temperature calculation by Shigeaki Koike

Speed 2.5mm/sec

Temperature distribution

New model EBW

3.8 Cavity Fabrication Facility (CFF) construction （３）

加速器だから見える世界。X band 60cm structure 11.424GHZ

High precision machining technology and disc diffusion bonding

Contour degree in the air fuselage ± 1 μm or less

Flatness of 0.5 μm or less

Surface roughness 0.05 μm Rz or less

Material: Oxygen-free copper (99.996%)

Use of vacuum chuck

and diamond tool

Heatherington Hydrogen

Atmospheric Furnace

Main dimensions

Joint surface inspection after diffusion bonding

Deformation after diffusion bonding＜０．０１％

3.9 X-band structure manufacturing technology development（１）


Development of in-line outer diameter measuring instrument

Capacitive sensor

Reference disk

Measurement disc

Capacitive displacement sensors fixed at regular intervals are

moved and compared with a standard dimensional disc.

Repeated measurement accuracy is ± 0.2 μm

0

20

40

60

80

100

120

140

160

-1.4

-1.3

-1.2

-1.1 -1

-0.9

-0.8

-0.7

-0.6

-0.5

-0.4

-0.3

-0.2

-0.1 0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9 1

1.1

1.2

1.3

1.4

1.5

1.6

1.7

erorr （μm)

ディ

スク

枚数

σ：0.35μｍ3σ：1.05μｍ

0

1

2

3

4

5

6

7

8

-1.5 -1 -0.5 0 0.5 1 1.5

Frequency deviation (MHz)

Popula

tion

Deviation from the design value:±０．００１ｍｍ

12.93±0.110.9297±0.002

φ2a

φ2b

φc

φ61±

0.0

02

X-band structure manufacturing technology application

Design and manufacture

of S-band RF gun

22 units have been

manufactured

Error（μｍ）

Frequency deviation（MHz）

3.9 X-band structure manufacturing technology development（２）

#of cells

#of cells


Unlike the

interferometry, it is

possible to measure

the shape of 5 nm

without using a

reference plane.

Measure the tilt angle of a surface with a laser

It is possible to measure shape mirrors that cannot be measured with conventional

interferometers.

Measurement of EUV mirror, etc.

Measuring principle Measuring equipment

1m diameter mirror Parabolic mirror Spherical mirror

3.10 Precision measurement without a reference plane


Actively engage in development work while making the best use of excellent

facilities, machine tools and using computer power.

Flux concentrator head

Precision mechanization,high precision,

high performance

Cavity manufacturing technology base with CFF as the corePrecision measuring device that applies precision/newly processing technology

New measurement method using gyro

Position tracking detector of J-PARC Muon g-2/EDM experiment

Crystal goniometer device

Mechanical engineering evolving with the evolution of accelerator science

Specific future research themesRecent research results

4. Basic research for next-generation of the mechanical engineering center

Recent research results


• Big projects related to accelerator science are carried out once every 20 or 30 years.

• Therefore, it is an important responsibility for MEC to work the pilot activities of the project.

• I would like to end my report with the hope of further development of personal connections and human resources.

• I hope for the further development of KEK.

5. Summary


1. KEK Applied Research Laboratory : 50 years of history 2021.3

2. KEK : Mechanical Engineering Center Activity Report 2004-2006,KEK Report 2008-4,June 2008 A/H

3. KEK : Mechanical Engineering Center Activity Report 2010-2016,KEK Progress Report 2017-11,February 2018 A

4. MEC Handbook Editorial Committee : Mechanical Engineering Center Handbook, 2002.3

5. Kume Tatsuya : Introducing KEK and Mechanical Engineering Center, 2008.12

These references are written in Japanese

Reference

evolving mechanical technology for high energy accelerator

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