Design process and series production of the intersection control rack for the European XFEL linear accelerator

The design and procurement of 98 Intersection Control Racks is part of the Spanish in-kind contribution to the European XFEL. This cabinet contains all the necessary electronics to control both the phase shifter and the quadrupole magnet positioning table that belong to the intersections of the undulator segments. A closed-loop control system has been developed, achieving a repeatability of less than 10 μm and 1 μm, respectively. Special care has been taken to get a repeatable design that minimizes electromagnetic noise and interference. Extensive tests have been conceived and applied to ensure reliable industrial production and quality assessment. Validation tests have been automated, facilitating the identification of defective components and unusual situations during serial production. This paper describes the Intersection Control Rack hardware and software, the design process, the quality assurance system and the main technical difficulties arisen at every design phase.