# Presentation: 004636

## ILC Electronics ManufacturingOpportunities

- ILC Industrial Forum at Fermilab
- September 21-22, 2005
- Ray Larsen for SLAC ILC Electronics Group

## Outline

- I. Power Electronics
- Modulators
- Power Supplies
- II. Controls & Networks
- III. Instrumentation

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## Subsystem Relative Costs

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## 2-Tunnel Model w/~Penetrations

**~6in. Penetration**

**Module **
**Tray**

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## I. Power Electronics

- Modulators
- Est. Production Cost 4% TPC
- Est. Range $100-200M
- Power Supplies
- Est. Production Cost ~4% TPC

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## Modulators: TESLA and Marx

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## Design Comparison

- 600 Units total
- Assume Dual Tunnels, short HV cables to klystron
- TESLA – Current Baseline design
- PFN, IGBT redundant switch at 1/10 HV, bouncer flattener, step-up Xfmr to 120KV, 140A
- MARX – R&D Design
- Potential 40-50% cost reduction, 10X lower switch current, losses.
- Plug-in module design to backplane, IGBT switch arrays each board, vernier board flattener, redundant switches, modules, diagnostic controllers, robotic module swap

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## Manufacturing Comparison

- TESLA:
- Traditional capacitor banks in cabinets, point-to-point interconnects, separate charging source at 10KV DC, separate dual discharge switch, separate oil-filled transformer.
- Entire unit can be contracted to assembler
- Could subcontract switches, transformer, HV cable assemblies, controls subassemblies
- Modulators and Xfmrs separately factory tested.

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## Manufacturing Comparison 2

- MARX
- Transformer-less oil-free design
- Each unit has 16 plug-in circuit board modules
- Total boards = 9600 for 600 units
- 60% Parts cost in IGBT switch sub-modules
- Total sub-modules =10 per module, 96,000 for 600 units
- Capacitors mount on each module
- Operates in sealed box with air-water heat exchanger
- Contract for fully assembled factory tested units
- Subcontract all subassemblies to standard PC board manufacturers.

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## Installation Comparison

- TESLA
- Install tested units in large cabinets, move units into tunnel position depending on how large can handle. May have to separate racks.
- Install transformer, HV connections separately
- Repair in situ or remove failed Xfmr
- MARX
- Install box 2x2x1.5m, populated with modules optional.
- Option: Populate, service with robotic module remove and replace system. Can work 24/7 from maintenance depots along machine.

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## Power Supplies

- High Availability 1/n Modular Designs where failure will interrupt machine
- Apply as needed to:
- KW to 100KW single load or string supplies
- Multi-channel Corrector supplies
- Cryogenic magnet supplies

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## HA PS Concept – Quads, LGPS

- n/N parallel modules for DC magnet supply (1/5 shown)
- Overall load current feedback
- Dual Diagnostics Controller Mezzanine Card each module

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## HA PS Module - Correctors, Cryo

- Motherboard
- Dual Serial Control IO
- Independent Carriers Hot Swappable
- Optional: Redundant n/N w/ Switchover
- Dual Bulk 48V DC In

**DC**
**Out**

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## Manufacturing

- Injection, Damping Ring and Beam Delivery all warm supplies, LGPS & Modular
- Main Linac quads, correctors cryogenic low voltage, high current, low power supplies
- Total units estimates
- LGPS 1/n redundant supplies:1500?
- Modular n-channel supplies: 3000?
- Cryogenic modular supplies: 3000

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## II. Controls & Networks

- Review of existing SLAC Linear Collider & PEP Control System
- Redundant DEC (HP) Alpha mainframes with 4 tandem processors each
- Remote Multibus SBC IOCs throughout systems
- IOCs fan out over multiple serial links to CAMAC simple communications controllers
- SLCnet, PEPnet, Pnet custom protocols
- Special fast timing net locked to Linac, PEP RF

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## Existing SLC Layout, Networks

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## SLC-PEP Controls Architecture

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## SLC-PEP Summary

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## SLC-PEP Upgrade Plan

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## SLC-PEP Upgrade Summary

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## ILC Proposed Architecture

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## ILC Proposed Summary

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## Central Controls Cluster

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## Linac Sector Nodes

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## Manufacturing

- Controls Est. = 4% of TPC.
- Propose all controls to be designed to HA platform.
- ATCA under study as candidate de facto standard.
- Modules, hardware, base software -- commercial contracts from standard suppliers.
- Custom design necessary for some data switching, fast timing modules; commercial manufacture.
- Total modules est. ~4,000 (not incl. instrumentation)
- Ethernet & Timing fiber plants substantial cost item.
- HA software major engineering effort, cost

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## III. Instrumentation

- Front End Instrument Modules Est. at 2.5% of TPC.
- Standard Packaging system required.
- Use ATCA HA packaging, concepts
- Some custom design necessary
- Assume 2-tunnel model for packaging
- R&D on Robotic Service System
- Assume 2-Tunnel Model
- Consider 1-Tunnel issues as backup (Cost vs. Availability)

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## ILC Linac Instrumentation (~40m)

- ~1m

- ATCA Standard
- Module

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## Sector Node Instrument Modules

- ATCA Style Carrier Modules, Hot Swappable
- ATM Mezzanine Modules, Hot Swappable
- Stand-Alone or Shelf Cluster
- Dual Redundant Serial I/O, Power
- Robotic Replaceable

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## Manufacturing

- All instrument packaging to be as far as possible in standard HA modules and hot-swappable sub-modules.
- Estimate ~ 1 ATCA carrier card w/ sub-modules per meter of machine, ~25,000 total carriers, 100,000 mezzanine modules.
- Standard hardware and PC board techniques.
- Custom designs for high performance, reliability, minimum cost.

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## Addenda: Single Tunnel Cost Study

- In 2001-2 post-Lehman Review studied placing instruments inside beam tunnel in concrete holes (TEEs) for radiation protection to reduce overall costs. Study known as CD0.4.
- Seemed feasible but for availability would need remote robotics servicing.
- Applied to BPMs, LLRF, vacuum pumps-gauges-valves, magnet movers, temperature, MPS-BCS-PPS...
- Note: Study was *not* for HA redundant design, did not estimate civil or robotics costs.

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## Lehman ($253M) vs. CD 0.4 ($118M) Potential Cost Reduction: $135M (53%)

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005

## Comment on Robotics Servicing

- Study of robotic service system conducted by J. Cornuelle in collaboration with Stanford ME department graduate engineering students. Simple manipulations of  removing, replacing modules in tunnel.
- Cost payback appears viable; major positive impact on availability (avoid machine shutdown to replace modules).
- Viability in dual tunnel also significant in providing 24/7 operation to minimize size, cost of crews.
- All ILC electronics systems planned to be modular, robotically serviceable, some hot-swappable.
- Significant manufacturer system opportunity.

- ILC Electronics Industrial Opps  R.S. Larsen

- September 21-22, 2005