Magnet array holder for accelerated assembly and improved alignment in vacuum electronics

Abstract

A magnet array holder configured to hold a magnet piece and / or a non-magnet piece to form a magnet array, the magnet array configured to manipulate one or more electron beams in a vacuum electronic device when assembled, the magnet array holder comprising: a set of slots configured to receive the magnet piece and / or the non-magnet piece; a set of pockets for accommodating the magnetic and / or non-magnetic parts; and one or more attachment interfaces configured to couple the magnet array holder to the vacuum electronic device.

Description

Technical Field

[0001] Embodiments of the present invention relate generally to vacuum electronics devices, and more particularly provide a magnet array holder for use in vacuum electronics devices to speed assembly and improve alignment, particularly when operating at millimeter wave frequencies and above. Background Art

[0002] A vacuum electronic device utilizes the interaction between one or more electron beams and one or more electromagnetic waves generated in an interaction region. The construction of a vacuum electronic device requires the incorporation of metals, ceramics, magnetics, and / or other types of materials into a single assembly. The assembly encloses a vacuum chamber or cavity in which the electron beam(s) and the electromagnetic wave(s) interact. Examples of vacuum electronic devices include, but are not limited to, particle accelerators, klystrons, gyrotrons, gyroklystrons, traveling wave tubes (TWT), gyro TWTs, backward wave oscillators, magnetrons, crossed field amplifiers, free electron lasers, wave beam injectors, and the like.

[0003] Electron beam propagation through the beam tunnel of a vacuum electron device is usually achieved using magnetic and / or electrostatic fields. In vacuum electron devices operating at millimeter and near-terahertz frequencies, magnetic fields are primarily used. Permanent magnets, electromagnets, and periodic magnet arrays are commonly used to confine the beam in the beam tunnel.

[0004] Challenges arise when assembling vacuum electron devices and preparing them for operation. First, due to manufacturing and assembly irregularities, the beam tunnel, magnetic centerline, and injection orientation of the beam are usually not aligned together. This challenge is particularly evident in high-frequency devices. Second, the quality of magnetic materials is usually not enough to ensure that the magnetic domains of individual magnets are aligned with the designed domains with the necessary accuracy, which results in an uneven magnetic field. Therefore, after manufacturing the vacuum electron beam device, technical experts spend a lot of time (e.g., several months) adjusting (fine-tuning) the magnetic field around the vacuum electronic device to achieve optimal beam transmission. In addition, the magnetic materials commonly used in vacuum electron devices have the highest level of magnetization and are therefore extremely difficult to handle. Their attractive and repulsive forces may be strong enough to cause breakage or the magnetic material to be deployed out of its proper orientation, which is not only inefficient for assembly but also dangerous to the assemblers.

[0005] Finally, magnets are usually secured with some kind of glue, which requires long curing times and great effort to hold the magnets accurately in their proper orientation for the extended curing time. This slows down the assembly process and introduces additional inaccuracies. Furthermore, the glue may cause inaccuracies in the position of the magnet pieces due to variations in the thickness of the glue joints. Misalignments can be linear, angular, height, and many other aspects. A magnet array assembled in a conventional manner may deviate from the design by a large percentage and therefore produce a magnetic field distribution that is far from ideal. This problem is exacerbated in devices operating at high frequencies or in devices requiring miniature (millimeter to sub-millimeter) magnet piece sizes, as joint tolerances are usually kept the same and therefore can add up to noticeable inhomogeneities.

[0006] The systems and methods will help facilitate the construction of vacuum electronics devices. Summary of the invention

[0007] Disclosed herein is a magnet array holder, a magnet array assembly and a corresponding method. Magnet arrays enable improved electron beam confinement, focusing and other types of manipulation in vacuum electronic devices. Magnet array holders enable accelerated assembly of magnet arrays, and are particularly suitable for automated production of vacuum electronic devices. In some embodiments, magnet array holders utilize mechanical fixtures to support and / or control the accurate positioning of each magnet piece and non-magnet piece while minimizing tolerance stacking. Magnet array holders also help control the shape and size of magnet pieces and non-magnet pieces themselves. Magnet array holders also support the insertion of magnet pieces and non-magnet pieces from one direction, simplifying process automation. Magnet array holders are also suitable for holding and assembling periodic permanent magnet arrays, Halbach magnet arrays, oscillator arrays, quadrupole magnet arrays, dipole magnet arrays and a mixture of multiple magnet array types (e.g., periodic permanent magnet arrays with quadrupole or dipole magnet arrays). The magnetic material of the magnet piece may include ferromagnetism, diamagnetic and paramagnetic. The magnet array holder can be used to fix the permanent magnet array and the electromagnet together to achieve the desired position accuracy and magnetic circuit performance. The non-magnetic piece can be used to space the magnet pieces at a desired distance to affect the magnetic circuit performance.

[0008] In some embodiments, the magnet array holder allows for the assembly of high strength magnet pieces that may be subject to attractive or repulsive forces during assembly, thereby avoiding significant challenges in manipulating the high strength magnet pieces into place. The magnet array holder significantly simplifies manual assembly of magnet arrays and also simplifies automation of the assembly process through robotic manipulation (e.g., pick and place systems).

[0009] The magnet array holder accurately positions magnet pieces in the proper orientation relative to each other and other magnet arrays for desired alignment. The positions of the magnet pieces can be accurately manufactured into the magnet holder with consistent precision using the latest manufacturing techniques, translating this precision directly into the assembly of the magnet pieces on the vacuum electronic device. The magnet array holder captures each magnet piece individually and securely so that the magnet array can be constructed without having to hold each magnet in place while the glue cures. In some embodiments, the magnet array holder and corresponding method of magnet array assembly eliminate the reliance on attempting to achieve uniform glue thickness individually or part by part.

[0010] The magnet array holder is particularly beneficial for planar magnetic structures employed in sheet electron beam devices or devices employing wiggler or undulator magnets. In other cases, the magnet array holder can be adapted for circular, hollow, gyratory, diverging, converging and multi-beam magnetic structures.

[0011] The present invention also provides an automated computer-implemented method for designing a magnet array holder for accurately manipulating an electron beam in a vacuum electronic device, wherein mechanical features are used to accurately position and secure magnet pieces and accelerate assembly. The magnet array holder can employ features for capturing magnet pieces and non-magnet pieces, marking features for aligning magnetic poles, heights of parts for holding and locating magnet pieces and non-magnet pieces, height variations, parts of varying lengths, additional parts for combining multiple magnet piece types, depths designed for locating magnets, single features for locating individual magnet pieces and magnet array orientations relative to other external magnets and non-magnetic features, fixtures for additional magnet pieces for shielding, combined depths and parts of other component walls, designs for predicting minimum and maximum misalignment of magnets, misalignment calculations for modeling magnetic circuit performance, and methods for various permanent and electro-permanent magnets.

[0012] The magnet array holder and technique disclosed herein are advantageous for achieving high quality alignment and are particularly advantageous for fabricating vacuum electron devices at millimeter wave and near THz frequencies. Vacuum electron devices using the magnet array holder designed herein can be configured to amplify electromagnetic signals in the frequency range of 1 GHz to 1000 GHz and up to 3 THz and / or 30 THz.

[0013] In some embodiments, the present invention provides a magnet array holder configured to hold magnet pieces and / or non-magnet pieces to form a magnet array, the magnet array being configured to manipulate one or more electron beams in a vacuum electronic device when assembled, the magnet array holder comprising: a set of slots configured to accommodate magnet pieces and / or non-magnet pieces; a set of recesses for accommodating magnet pieces and / or non-magnet pieces; and one or more attachment interfaces ((one or more) holes, (one or more) pins, (one or more) glues, (one or more) clamps, (one or more) welds, attachment materials, etc.), configured to couple the magnet array holder to a vacuum electronic device. In some embodiments, the magnet array holder 202 can be integrated as part of the vacuum electronic device 100.

[0014] Each groove in the group of grooves can have a first shape, and each recess in the group of recesses can have a second shape different from the first shape. Each recess in the group of recesses can have a bridge across it. Each recess in the group of recesses can include a mark indicating the orientation of the magnet piece to help align the magnet piece. The mark can include a written symbol description (written key). Each recess can have a size, shape and position that controls the size, shape and position of the magnet piece or non-magnet piece contained therein. Each groove can have a size, shape and position that controls the size, shape and position of the magnet piece or non-magnet piece contained therein. The magnet array holder can also include a group of additional parts, which are configured to accommodate additional magnet pieces or non-magnet pieces. Each part of the group of additional parts can include a mark indicating the orientation of the magnet piece to help align the additional magnet piece. At least one groove in the group of grooves can extend through the magnet array holder. The magnet array holder can hold both magnet pieces and non-magnet pieces. The magnet array holder can only hold magnet pieces. The magnet array holder can only hold a part of the magnetic circuit required for the operation of the vacuum electronic device.

[0015] In some embodiments, the present invention provides a method for assembling a magnet array configured to manipulate one or more electron beams in a vacuum electronic device, the method comprising: providing a magnet array holder configured to maintain magnetic pieces and / or non-magnetic pieces, the magnet array holder comprising a group of slots configured to accommodate magnetic pieces and / or non-magnetic pieces, a group of recesses for accommodating magnetic pieces and / or non-magnetic pieces, and one or more interfaces for fixing or attaching to couple to a vacuum electronic device; positioning at least one pair of magnetic pieces or non-magnetic pieces within the group of slots, adjacent to specific recesses in the group of recesses; and positioning a specific magnetic piece within a specific recess of the group of recesses, the pair of magnetic pieces or non-magnetic pieces acting as walls to support the insertion of the specific magnetic piece.

[0016] Each recess in the group of recesses may have a bridge across it. Each slot in the group of slots may be configured to accommodate a corresponding non-magnetic piece. Each slot in the group of slots may be configured to accommodate a magnet piece having an up / down polarization orientation. Positioning a particular magnet piece in a particular recess may include orienting its polarity according to a marking. The magnet array holder may also include a group of additional locations configured to accommodate additional magnet pieces and / or non-magnetic pieces; and the method may also include positioning the additional magnet pieces in the additional locations. Positioning the additional magnet pieces and / or non-magnetic pieces may include orienting the polarity according to a marking.

[0017] The disclosure described herein provides an example of applying slotting techniques to the assembly of rectangular magnets. The same method using slot depth and varying piece height can be used to assemble cylindrically symmetrical magnets and non-magnets. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 Components of an example vacuum electronic device, such as an example traveling wave tube (TWT), are shown showing an example magnet array attached thereto in accordance with an embodiment of the present invention.

[0019] Figure 2a A top perspective view of an example magnet array according to some first embodiments of the present invention is shown.

[0020] Figure 2b A bottom perspective view of an example magnet array according to some first embodiments of the present invention is shown.

[0021] Figure 2c Top and bottom views of an example magnet array holder according to some first embodiments of the present invention are shown.

[0022] Figure 2d A top perspective view of an example magnet array holder according to some first embodiments of the present invention is shown.

[0023] Figure 2e A bottom perspective view of an example magnet array holder according to some first embodiments of the present invention is shown.

[0024] Figure 2f Top and bottom views of an example magnet array according to some first embodiments of the present invention are shown.

[0025] Figure 2g A side view of an example magnet array according to some first embodiments of the present invention is shown.

[0026] Figure 2h A cross-sectional side view of an example magnet array according to some first embodiments of the present invention is shown.

[0027] Figure 3aA top perspective view of an example magnet array holder according to some first embodiments of the present invention is shown.

[0028] Figure 3b A top perspective view of an example magnet array holder is shown with one magnet piece positioned therein according to some first embodiments of the present invention.

[0029] Figure 3c A top perspective view of an exemplary magnet array holder is shown according to some first embodiments of the present invention, wherein one magnet piece and one non-magnet piece are positioned.

[0030] Figure 3d A top perspective view of an example magnet array holder according to some first embodiments of the present invention is shown with all magnet pieces and all non-magnet pieces positioned.

[0031] Figure 4a A top perspective view of an example magnet array according to some second embodiments of the present invention is shown.

[0032] Figure 4b A bottom perspective view of an example magnet array according to some second embodiments of the present invention is shown.

[0033] Figure 4c A bottom perspective view of an example magnet array according to some third embodiments of the present invention is shown.

[0034] Figure 4d Top and bottom views of example magnet array holders according to some second embodiments of the present invention are shown.

[0035] Figure 4e A top perspective view of an example magnet array holder according to some second embodiments of the present invention is shown.

[0036] Figure 4f A bottom perspective view of an example magnet array holder according to some second embodiments of the present invention is shown.

[0037] Figure 4g A bottom view of an example magnet array holder according to some third embodiments of the present invention is shown.

[0038] Figure 4h A top perspective view of an example magnet array holder according to some third embodiments of the present invention is shown.

[0039] Figure 4i A bottom perspective view of an example magnet array holder according to some third embodiments of the present invention is shown.

[0040] Figure 4j Top and bottom views of example magnet arrays according to some second embodiments of the present invention are shown.

[0041] Figure 4k A side view of an example magnet array according to a second embodiment of the present invention is shown.

[0042] Figure 4l A cross-sectional side view of an example magnet array according to a second embodiment of the present invention is shown.

[0043] Figure 4m A bottom view of an example magnet array according to some third embodiments of the present invention is shown.

[0044] Figure 5a A top perspective view of an example magnet array holder according to some second embodiments of the present invention is shown.

[0045] Figure 5b A top perspective view of an example magnet array holder according to some second embodiments of the present invention is shown with one magnet piece positioned therein.

[0046] Figure 5c A top perspective view of an exemplary magnet array holder is shown according to some second embodiments of the present invention, wherein one magnet piece and one non-magnet piece are positioned.

[0047] Figure 5d A top perspective view of an example magnet array holder according to some second embodiments of the present invention is shown, with all magnet pieces and all non-magnet pieces positioned.

[0048] Figure 6a A bottom perspective view of an example magnet array holder is shown with one magnet piece positioned therein according to some third embodiments of the present invention.

[0049] Figure 6b A bottom perspective view of an example magnet array holder according to some third embodiments of the present invention is shown with all magnet pieces positioned.

[0050] Figure 7a A side view of an example top magnet array is shown in accordance with some embodiments of the present invention.

[0051] Figure 7b A side view of an example bottom magnet array is shown in accordance with some embodiments of the present invention.

[0052] Figure 7c A cross-sectional side view of an example top magnet array is shown in accordance with some embodiments of the present invention.

[0053] Figure 7d A cross-sectional side view of an example bottom magnet array is shown in accordance with some embodiments of the present invention. DETAILED DESCRIPTION

[0054] Disclosed herein is a magnet array holder, a magnet array assembly and a corresponding method. Magnet arrays enable improved electron beam confinement, focusing and other types of manipulation in vacuum electronic devices. Magnet array holders enable accelerated assembly of magnet arrays, and are particularly suitable for automated production of vacuum electronic devices. In some embodiments, magnet array holders utilize mechanical fixtures to support and / or control the accurate positioning of each magnet piece and non-magnet piece while minimizing tolerance stacking. Magnet array holders also help control the shape and size of magnet pieces and non-magnet pieces themselves. Magnet array holders also support the insertion of magnet pieces and non-magnet pieces from one direction, simplifying process automation. Magnet array holders are also suitable for holding and assembling periodic permanent magnet arrays, Halbach magnet arrays, oscillator arrays, quadrupole magnet arrays, dipole magnet arrays and a mixture of multiple magnet array types (e.g., periodic permanent magnet arrays with quadrupole or dipole magnet arrays). The magnetic material of the magnet piece may include ferromagnetism, diamagnetic and paramagnetic. The magnet array holder can be used to fix the permanent magnet array and the electromagnet together to achieve the desired position accuracy and magnetic circuit performance. The non-magnetic piece can be used to space the magnet pieces at a desired distance to affect the magnetic circuit performance.

[0055] In some embodiments, the magnet array holder allows for the assembly of high strength magnet pieces that may be subject to attractive or repulsive forces during assembly, thereby avoiding significant challenges in manipulating the high strength magnet pieces into place. The magnet array holder significantly simplifies manual assembly of magnet arrays and also simplifies automation of the assembly process through robotic manipulation (e.g., pick and place systems).

[0056] The magnet array holder accurately positions the magnet pieces in the proper orientation relative to each other and other magnet arrays for the desired alignment. The magnet array holder captures each magnet piece individually and securely so that the magnet array can be constructed without having to hold each magnet in place while the glue cures. In some embodiments, the magnet array holder and corresponding method of magnet array assembly eliminates the reliance on trying to achieve uniform glue thickness individually or part by part.

[0057] The magnet array holder is particularly beneficial for planar magnetic structures employed in sheet electron beam devices or devices employing wiggler or undulator magnets. In other cases, the magnet array holder can be adapted for circular, hollow, gyratory, diverging, converging and multi-beam magnetic structures.

[0058] The present invention also provides an automated computer-implemented method for designing a magnet array holder for accurately manipulating an electron beam in a vacuum electronic device, wherein mechanical features are used to accurately position and secure magnet pieces and accelerate assembly. The magnet array holder can employ features for capturing magnet pieces and non-magnet pieces, marking features for aligning magnetic poles, heights of parts for holding and locating magnet pieces and non-magnet pieces, height variations, parts of varying lengths, additional parts for combining multiple magnet piece types, depths designed for locating magnets, single features for locating individual magnet pieces and magnet array orientations relative to other external magnets and non-magnetic features, fixtures for additional magnet pieces for shielding, combined depths and parts of other component walls, designs for predicting minimum and maximum misalignment of magnets, misalignment calculations for modeling magnetic circuit performance, and methods for various permanent and electro-permanent magnets.

[0059] The magnet array holder and technique disclosed herein are advantageous for achieving high quality alignment and are particularly advantageous for fabricating vacuum electron devices at millimeter wave and near THz frequencies. A vacuum electron device using the magnet array holder designed herein can be configured to amplify electromagnetic signals in the frequency range of 1 GHz to 1000 GHz.

[0060] Figure 1 Components of an example vacuum electron device 100, such as an example traveling wave tube (TWT) 100, are shown with a magnet array 110 (magnet array assembly) attached thereto in accordance with some embodiments of the present invention. Figure 1 Although shown with respect to a TWT, the magnet array 110 herein may be used with any vacuum electron device 100 that uses a magnet assembly to manipulate one or more electron beams in an interaction region.

[0061] The TWT 100 includes a TWT gun 102 configured to generate one or more electron beams (transmitting in the z direction). The TWT gun 102 can be used for sheet beams, hollow beams, pencil beams, distributed beams, multiple beams, etc. The TWT 100 also includes an interaction loop, which includes an RF input window 104, an RF output window 106 and two magnet arrays 110, which are configured to guide and shape one or more electron beams through the interaction loop. The two magnet arrays 110 include a top magnet array 110 shown on the top of the TWT 100 and a bottom magnet array on the bottom of the TWT 100 as a mirror image. Although Figure 1 The bottom magnet array 110 is not clearly shown in FIG. 1 , but iron shields of the top and bottom magnet arrays 110 are shown. The TWT 100 also includes a TWT collector 108 configured to collect one or more electron beams transmitted through the TWT 100 .

[0062] Figure 2a A top perspective view of an example magnet array 110 according to some first embodiments of the present invention is shown. The magnet array 110 includes a magnet array holder 202, a magnet piece 204 positioned in a portion in the magnet array holder 202, a non-magnet piece 206 positioned in a portion in the magnet array holder 202, and an iron shield 208 positioned on the front edge of the magnet array holder (the side of the TWT 100 near the TWT gun 102).

[0063] The magnet array holder 202 may be made of non-magnetic materials, such as aluminum or its aluminum alloys, titanium or its alloys, copper or its alloys, and / or stainless steel, etc. Magnetic materials may be used to create all or part of the magnet array holder 202 to achieve desired magnetic circuit properties and, therefore, a desired magnetic field.

[0064] These locations provide example mechanical features to accurately hold the magnetic and non-magnetic parts in place. Example locations (at least Figure 2d and Figure 2e 204 can be positioned in a recess, and the non-magnetic member 206 can be positioned in a slot. Alternatively, both can be positioned in a recess, both can be positioned in a slot, the magnetic member 204 can be positioned in a recess and / or a slot, and / or the non-magnetic member 206 can be positioned in a recess and / or a slot. Any combination is possible.

[0065] Each part (recess, slot or cutout) controls the position, size and orientation of the magnet piece 204 and / or the non-magnet piece 206. Position and size include length, depth, width, vertical position (y-axis), lateral position (x-axis), longitudinal position (z-axis), etc.). These parts can be implemented symmetrically or asymmetrically to achieve the desired results. The position and size of each part and the corresponding magnet piece 204 and non-magnet piece 206 placed therein can be modeled to achieve the desired magnetic interaction loop performance.

[0066] The magnetic pieces 204 and non-magnetic pieces 206 can be fixed to their respective locations without the need for immediate application of glue. In some embodiments, when glue is added, the glue does not affect the positioning of the magnetic pieces 204 and / or non-magnetic pieces 206. In some embodiments, each location can be configured to accommodate more than one magnetic piece 204, more than one non-magnetic piece 206, and / or a combination of magnetic pieces 204 and non-magnetic pieces 206.

[0067] It should be understood that the height of the magnet pieces 204 and / or non-magnet pieces 206 can be varied to provide desired gaps between individual magnet pieces 204 and non-magnet pieces 206. The automated assembly process can take advantage of the extra height to grab the magnet pieces 204 and non-magnet pieces 206 and insert them into the corresponding positions. Height variations can be used to insert the magnet pieces 204 and / or non-magnet pieces 206 in a desired order. The height of the magnet pieces 204 and / or non-magnet pieces 206 can also be modeled to achieve desired magnetic interaction loop performance.

[0068] Similar to the length, height, and width, the depth of the magnet pieces 204 and non-magnet pieces 206 can be used to provide additional isolation and alignment levels between different types of magnet pieces 204 and / or non-magnet pieces 206 in the assembly. The walls of the site can be configured to act as additional constraints on the magnet pieces 204 as they are inserted and after they have been inserted into the site. The depth can provide positional positioning accuracy.

[0069] As shown, the exposed side of the example magnet array 110 includes an alternating sequence of magnet pieces 204 and non-magnet pieces 206 across the length of the magnet array holder 202, although other sequences are possible based on the desired magnetic interaction circuit performance. As shown, the magnet pieces 204 are positioned so that their upper surfaces vertically terminate in a single plane that is higher than the non-magnet pieces 206, which also terminate in a single plane.

[0070] The magnet array holder 202 can be configured for vacuum electronic devices operating at a variety of frequencies, but it is particularly advantageous for devices operating between 25 GHz and 1 THz. The magnet array holder 202 is particularly suitable for the size range of electronic devices from microns to millimeters, and thus supports the fabrication and alignment required for electron beams to propagate through interaction loops. The magnet array 110 can be configured to amplify electromagnetic signals having frequencies ranging from 1 GHz to 25 GHz, frequencies ranging from 25 GHz to 100 GHz, frequencies ranging from 100 GHz to 250 GHz, frequencies ranging from 250 GHz to 500 GHz, or frequencies ranging from 500 GHz to 1000 GHz. Other frequency ranges are also possible.

[0071] Although the magnet array holder 202 is shown as including a slot 214 extending through the entire magnet array holder 202, in some embodiments, the magnet array holder 202 may include a solid bottom plate, such as on the bottom side of the magnet array holder 202, such that the non-magnetic pieces 206 cannot extend beyond the bottom plate.

[0072] The disclosure described herein provides an example of applying slotting techniques to the assembly of rectangular magnets. The same method using slot depth and varying piece height can be used to assemble cylindrically symmetrical magnets and non-magnets.

[0073] Figure 2b A bottom perspective view of an example magnet array 110 according to some first embodiments of the present invention is shown. Additional magnet members 210 may be included to combine magnetic circuit types. The additional magnet members 210 may be quadrupole and / or dipole magnet members 210 configured to add additional magnetic control of one or more electron beams. The additional magnet members 210 may be positioned in a recessed location (more specifically, in Figure 2e As shown, the additional magnet pieces 210 may be positioned as an array of two additional pieces 210 below each magnet piece 204 in the sequence of magnet pieces 204. Although shown below, the additional magnet pieces 210 may be positioned in any other position, such as above, adjacent, etc.

[0074] In some embodiments, the magnet assembly 204 and the non-magnet assembly 206 are configured to steer one or more electron beams in the y-direction. In some embodiments, the additional magnet assembly 210 is configured to steer one or more electron beams in the x-direction.

[0075] Figure 2c Top and bottom views of a magnet array holder 202 are shown according to some first embodiments of the present invention.

[0076] In some embodiments, as shown, the top side of the magnet array holder 202 includes a slot 214 for accommodating the non-magnetic piece 206 and a recess 216 for accommodating the magnet piece 204. In some embodiments, as shown, the bottom side of the magnet array holder 202 includes a recess 218 for accommodating the additional (quadrupole) magnet piece 210. The slot 214, recess 216, and recess 218 may be collectively referred to as a region 228.

[0077] Markings 212 may be added to the recesses 216 of the magnet array holder 202 to identify the magnet polarity of the magnet piece 204 to be placed therein so that an assembler can match the markings 212 during the assembly process to ensure proper magnet orientation. The markings 212 may be added to either or both of the magnet piece 204 and the magnet array holder 202. It should be understood that the markings 212 may include written markings 212 or physical markings 212 (i.e., symbolic instructions) to ensure proper orientation of the magnet piece 204 during assembly.

[0078] In some embodiments, as shown, markings 212 on the top (exposed) side of the magnet array holder 202 depict an alternating pattern of north and south magnet pieces 204 to be positioned in pockets 216. In some embodiments, as shown, markings 212 on the bottom side (the side positioned against the TWT 100) of the magnet array holder 202 depict an array of south or north or opposite additional (quadrupole) magnet pieces 204 to be positioned in pockets 218.

[0079] In some embodiments, the size and shape of each of the grooves 214 may be the same, the size and shape of each of the recesses 216 may be the same, and the size and shape of each of the recesses 218 may be the same. In some embodiments, the size and shape of each of the grooves 214, recesses 216, and recesses 218 may each be the same or different. In some embodiments, the size and shape of each of the grooves 214, the size and shape of each of the recesses 216, and the size and shape of each of the recesses 218 may vary. Any combination is possible.

[0080] The fixture may also help align additional external magnet pieces, such as magnetic shields, outside the magnet array 110. Additional external pockets or cutouts and alignment features may be added to locate and secure them in place. The external magnet pieces may be part of a complete or partial magnetic circuit.

[0081] Figure 2d A top perspective view of a magnet array holder 202 according to some first embodiments of the present invention is shown. The magnet array holder 202 includes an alternating sequence of slots 214 for accommodating non-magnetic pieces 206 and recesses 216 for accommodating magnet pieces 204. The magnet array holder 202 also includes one or more (three in this case) attachment interfaces 220 (e.g., rectangular protrusions with (one or more) screw holes as shown, or additional or alternative (one or more) pins, (one or more) glues, (one or more) clamps, (one or more) welds, attachment materials, etc.) for attaching the magnet array holder 202 to the vacuum electron device 100. In some embodiments, the magnet array holder 202 can be integrated as part of the vacuum electron device 100.

[0082] Figure 2e A bottom perspective view of a magnet array holder 202 according to some first embodiments of the present invention is shown. The magnet array holder 202 includes an array of pockets 216 for receiving additional magnet pieces 210, such as quadrupole magnet pieces.

[0083] Figure 2f A top view and a bottom view of a magnet array 110 according to some first embodiments of the present invention are shown. As shown, the magnet array 110 includes holes 224 for aligning the magnet array 110.

[0084] Figure 2gA side view of a magnet array 110 according to some first embodiments of the present invention is shown. As shown, the magnet array 110 includes a magnet array holder 202 having an iron shield 208 attached to a front edge, followed in this embodiment by an alternating sequence of magnet pieces 204 and non-magnet pieces 206. Other patterns of magnet pieces 204 and non-magnet pieces 206 are possible to achieve the desired interaction.

[0085] Figure 2h A cross-sectional side view of a magnet array 110 is shown according to some first embodiments of the present invention. Figure 2h The magnet array 110 in the figure helps to show the depth, height position and height of the magnet pieces 204 and non-magnet pieces 206. In some embodiments, as shown, the magnet pieces 204 are placed on top of the sequence of bridges 226 set on the bottom of the magnet array holder 202, and the non-magnet pieces 206 extend between and extend beyond the bridges 226, extending completely to (or some embodiments exceed) the bottom surface of the magnet array holder 202. In some embodiments, the magnet array holder 202 can include a sequence of bridges below the non-magnet pieces 206, and does not include a sequence of bridges below the magnet pieces 204. In some embodiments, the magnet array holder 202 can include a sequence of bridges below the combination of magnet pieces 204 and non-magnet pieces 206 (e.g., some or all of each). In some embodiments, the magnet array holder 202 can include a sequence of bridges below the combination of magnet pieces 204 and non-magnet pieces 206. In some embodiments, the magnet array holder 202 can include a sequence of ceilings as an alternative or supplement to bridges, particularly when the magnet pieces 204 and / or non-magnet pieces 206 are assembled from below rather than above. Similarly, in some embodiments, the magnet array holder 202 may include a wall as an alternative or in addition to a bridge or ceiling, particularly when the magnet pieces 204 and / or non-magnet pieces are assembled from the side rather than from above or below. Other orientations are also possible. Combinations of different orientations are also possible.

[0086] Figure 3a-3d An example assembly process of the magnet array 110 using an example magnet array holder 202 is shown. Figure 3a A top perspective view of a magnet array holder 202 according to some first embodiments of the present invention is shown. As shown, an iron shield 208 is attached to the front edge of the magnet array holder 202. Figure 3b A top perspective view of a magnet array holder 202 is shown in accordance with some first embodiments of the present invention, wherein one magnet piece 204 is positioned adjacent to an iron shield 208 and may serve as a fixture for insertion of the next piece. Figure 3c A top perspective view of a magnet array holder 202 is shown in accordance with some first embodiments of the present invention, wherein one magnet piece 204 and one non-magnet piece 206 are positioned adjacent the magnet piece 204 and may serve as a fixture for the insertion of the next component. Figure 3d A top perspective view of a magnet array holder 202 is shown with all magnet pieces 204 and all non-magnet pieces 206 positioned therein to form a magnet array 110 in accordance with some first embodiments of the present invention.

[0087] In some embodiments, the pattern for assembly of the magnet array 110 begins with inserting the non-magnetic pieces 206, or at least pairs of magnet pieces 206, into their respective slots 214. Because the non-magnetic pieces 206 do not interfere with each other, the non-magnetic pieces 204 can be inserted without difficulty. Then, the magnet pieces 204 can be inserted into the recesses 216 between the pairs of non-magnetic pieces 206. The pairs of non-magnetic pieces 206 establish a fixture / wall for the magnet pieces 204 so that the attractive and repulsive forces can be supported during insertion, thereby reducing the risk of fracture of the magnet pieces 204 (which may be brittle) and the risk of the magnet pieces 204 being pushed in. It should be understood that this pattern can be similarly used for the assembly of a magnet array 400 that includes an alternating sequence of up / down polarized magnet pieces and left-right polarized magnet pieces. The pattern may start with positioning the up-down or left-right polarized magnet pieces in the slots, and then adding left-right or up-down polarized pieces between each pair of up / down polarized pieces.

[0088] Compared to conventional assembly, assembly time is reduced to approximately one-tenth. Alignment is predictable and can be accurately calculated. This allows detailed study of the effects of tolerances of the individual magnet pieces 204 and the magnet array holder 202 itself as it relates to the performance of the magnetic circuit design and the fields generated to steer the electron beam.

[0089] Figure 4a A top perspective view of an example magnet array 400 according to some second embodiments of the present invention is shown. Similar to the magnet array 110, the magnet array 400 includes a magnet array holder 402, an iron shield 408, magnet pieces 404 in pockets, and non-magnetic pieces 406 in slots. The magnet array 400 is similar to the magnet array 110, except that the magnet array holder 402, magnet pieces 404, non-magnetic pieces 406, and iron shield 408 are shaped differently.

[0090] Figure 4b A bottom perspective view of an example magnet array 400 according to some second embodiments of the present invention is shown. The magnet array holder 402 does not include additional pockets on the bottom side for additional magnet pieces, such as quadrupole magnet pieces.

[0091] Figure 4cA bottom perspective view of an example magnet array 410 according to some third embodiments of the present invention is shown. The magnet array 410 may include the same top side as the magnet array 400. However, the magnet array 410 may include a magnet array holder 412 having a different bottom side that includes additional pockets configured to accommodate additional (quadrupole) magnet pieces 414 contained therein.

[0092] Figure 4d A top view and a bottom view of a magnet array holder 402 according to some second embodiments of the present invention are shown. In some embodiments, as shown, the top side of the magnet array holder 402 includes a slot 418 for accommodating a non-magnetic piece 406 and a recess 420 for accommodating a magnet piece 404. The slot 418 and the recess 420 may be collectively referred to as a site 428. A mark 416 may be added to the recess 420 of the magnet array holder 402 to identify the magnet polarity of the magnet piece 404 to be placed therein, so that the assembler can match the mark 416 during the assembly process to ensure proper magnet orientation. The mark 416 may be added to either or both of the magnet piece 404 and the magnet array holder 402. It should be understood that the mark 416 may include a written mark 416 or a physical mark 416 (i.e., a symbolic description) to ensure proper orientation of the magnet piece 404.

[0093] In some embodiments, as shown, indicia 212 on the top (exposed) side of the magnet array holder 202 depict an alternating pattern of north and south pointing magnet pieces 204 to be positioned in pockets 216 .

[0094] Figure 4e A top perspective view of a magnet array holder 402 according to some second embodiments of the present invention is shown. The magnet array holder 402 includes an alternating sequence of slots 418 for accommodating non-magnetic pieces 406 and pockets 420 for accommodating magnet pieces 404. The magnet array holder 402 also shows a bridge at the bottom of the pockets 420.

[0095] Figure 4f A bottom perspective view of a magnet array holder 402 according to some second embodiments of the present invention is shown. The magnet array holder 402 does not include an array of pockets for accommodating additional magnet pieces (e.g., quadrupole magnet pieces). The magnet array holder 402 shows an opening for a slot for accommodating a non-magnet piece 406.

[0096] Figure 4g A bottom view of a magnet array holder 412 according to some third embodiments of the present invention is shown. In some embodiments, the bottom side of the example magnet array holder 412 includes pockets 424 for additional (quadrupole) magnet pieces 414, as shown.

[0097] Markings 422 may be added to the recesses 424 of the magnet array holder 402 to identify the magnet polarity of the magnet piece 414 to be placed therein so that the assembler can match the markings 414 during the assembly process to ensure proper magnet orientation. The markings 414 may be added to either or both of the magnet piece 414 and the magnet array holder 412. It should be understood that the markings 422 may include written markings 422 or physical markings 422 (i.e., symbolic instructions) to ensure proper orientation of the magnet piece 414. In some embodiments, as shown, the markings 422 on the bottom side of the magnet array holder 412 (the side that is positioned against the TWT 100) depict a pattern of additional (quadrupole) magnet pieces 414 to be positioned in the recesses 424, either south or north or opposite.

[0098] Figure 4h A top perspective view of a magnet array holder 412 according to some third embodiments of the present invention is shown. The magnet array holder 412 includes an alternating sequence of slots 418 for receiving non-magnetic pieces 406 and pockets 420 for receiving magnet pieces 404.

[0099] Figure 4i A bottom perspective view of a magnet array holder 412 according to some third embodiments of the present invention is shown. The magnet array holder 412 includes an array of pockets 424 for receiving additional magnet pieces 414, such as quadrupole magnet pieces.

[0100] Figure 4j The top view and the bottom view of the magnet array 400 according to some second embodiments of the present invention are shown. As shown, the magnet array 400 includes a hole 420 for aligning the magnet array 110.

[0101] Figure 4k A side view of a magnet array 400 / 410 according to a second embodiment of the present invention is shown. As shown, the magnet array 400 / 410 includes a magnet array holder 402 / 412 having an iron shield 408 attached to the front edge, which in this embodiment is followed by an alternating sequence of magnet pieces 404 and non-magnet pieces 406. Other patterns of magnet pieces 404 and non-magnet pieces 406 are also possible to achieve the desired interaction.

[0102] Figure 4l A cross-sectional side view of a magnet array 400 / 410 is shown in accordance with a second embodiment of the present invention. Figure 4lThe magnet array 400 / 410 in the figure helps to illustrate the depth, height position and height of the magnet pieces 404 and non-magnet pieces 406. In some embodiments, as shown, the magnet pieces 404 are placed on top of a sequence of bridges 434 disposed on the bottom of the magnet array holder 402, and the non-magnet pieces 406 extend between and beyond the bridges 434, extending completely to (or in some embodiments beyond) the bottom surface of the magnet array holder 402.

[0103] Figure 4m A bottom view of a magnet array 410 according to some third embodiments of the present invention is shown. As shown, the magnet array 410 includes holes 432 for aligning the magnet array 410.

[0104] Figure 5a-5d An example assembly process of a magnet array 400 using an example magnet array holder 402 is shown. Figure 5a A top perspective view of a magnet array holder 402 according to some first embodiments of the present invention is shown. As shown, an iron shield 408 is attached to the front edge of the magnet array holder 402. Figure 5b A top perspective view of a magnet array holder 402 is shown in accordance with some first embodiments of the present invention, wherein one magnet piece 404 is positioned adjacent to an iron shield 408 and may serve as a fixture for insertion of the next piece. Figure 5c A top perspective view of a magnet array holder 402 is shown according to some first embodiments of the present invention, wherein one magnet piece 404 and one non-magnet piece 406 are positioned adjacent to the magnet piece 404 and may serve as a fixture for the insertion of the next component. Figure 5d A top perspective view of a magnet array holder 402 is shown with all magnet pieces 404 and all non-magnet pieces 406 positioned therein to form a magnet array 400 in accordance with some first embodiments of the present invention.

[0105] and Figure 3a-3dSimilarly, in some embodiments, the pattern for assembly of the magnet array 400 begins with inserting the non-magnetic pieces 406, or at least pairs of magnet pieces 406, into their respective slots 418. Because the non-magnetic pieces 406 do not interfere with each other, the non-magnetic pieces 406 can be inserted without difficulty. Then, the magnet pieces 404 can be inserted into the recesses 420 between the pairs of non-magnetic pieces 406. The pairs of non-magnetic pieces 406 establish a fixture / wall for the magnet pieces 404 so that the attractive and repulsive forces can be supported during insertion, thereby reducing the risk of fracture of the magnet pieces 404 (which may be brittle) and the risk of the magnet pieces 404 being pushed in. It should be understood that this pattern can be similarly used for the assembly of a magnet array 400 that includes an alternating sequence of up / down polarized magnet pieces and left-right polarized magnet pieces. The pattern may start with positioning up-down or left-right polarized magnet pieces, or at least pairs of up / down polarized magnet pieces, in the slots, and then adding left-right or up-down polarized pieces between each pair of up / down or left-right polarized pieces.

[0106] Figure 6a-6b An example assembly process of a magnet array 410 using an example magnet array holder 412 is shown. Figure 6a A bottom perspective view of a magnet array holder 412 is shown with one magnet member 414 positioned therein, in accordance with some third embodiments of the present invention. Figure 6b A bottom perspective view of a magnet array holder 412 is shown with all magnet pieces 414 positioned according to some third embodiments of the present invention.

[0107] Figure 7a-7d An example top magnet array 700 and bottom magnet array 702 are shown for establishing confinement and steering of one or more electron beams. The positioning of individual magnet pieces 404 relative to the top and bottom magnet arrays 700, 702 can be critical to the performance of the vacuum electron device 100. Figure 7a A side view of a top magnet array 700 is shown in accordance with some embodiments of the present invention. Magnet arrays 110 , 400 , and 410 are each examples of top magnet array 700 . Figure 7b A side view of a bottom magnet array 702 is shown in accordance with some embodiments of the present invention. Magnet arrays 110, 400, and 410 are each examples of bottom magnet array 702. Figure 7c A cross-sectional side view of a top magnet array 700 is shown in accordance with some embodiments of the present invention. Figure 7d A cross-sectional side view of a bottom magnet array 702 is shown in accordance with some embodiments of the present invention.

[0108] In some embodiments, the magnet array holder 202 / 402 / 412 can only support magnet pieces. In some embodiments, non-magnet separators can be built into the magnet array holder 202 / 402 / 412 to replace some or all of the non-magnet pieces. In some embodiments, the magnet array holder 202 / 402 / 412 can be designed to include only a portion of the interaction loop so that other magnets can be positioned elsewhere, for example, on one or more second magnet array holders, on the vacuum electronic device itself, etc. In some embodiments, the magnet array holder 202 / 402 / 412 can include a magnetic portion to replace some of the magnet pieces. In some embodiments, different locations 202 / 402 / 412 can be designed to accommodate a set of alternating magnet pieces 204 / 404 of opposite polarity without non-magnet pieces 206 / 406. Other combinations are also possible.

[0109] The above description of the preferred embodiments of the present invention is for example only, and other variations and modifications of the above embodiments and methods are possible according to the above teachings. The embodiments described herein are not intended to be exhaustive or limiting. The present invention is limited only by the appended claims.

Claims

1. A magnet array holder configured to hold magnet pieces and / or non-magnet pieces to form a magnet array, the magnet array being configured to manipulate one or more electron beams in a vacuum electron device when assembled, the magnet array holder comprising: a set of slots configured to receive magnetic pieces and / or non-magnetic pieces; a set of recesses for receiving magnetic and / or non-magnetic components; as well as One or more attachment interfaces configured to couple the magnet array holder to a vacuum electron device. 2 . The magnet array holder of claim 1 , wherein each slot in the set of slots has a first shape, and each recess in the set of recesses has a second shape different from the first shape.

3. The magnet array holder of claim 1 , wherein each well in the set of wells has a bridge across it.

4. The magnet array holder of claim 1, wherein each recess in the set of recesses includes markings indicating the orientation of the magnet piece to assist in aligning the magnet piece.

5. The magnet array holder of claim 4, wherein the marking is a written symbolic description.

6. The magnet array holder of claim 1, wherein each pocket has a size, shape and position that controls the size, shape and position of the magnetic or non-magnetic piece received therein.

7. The magnet array holder of claim 1, wherein each slot has a size, shape and position that controls the size, shape and position of the magnetic or non-magnetic piece received therein.

8. The magnet array holder of claim 1, further comprising a set of additional locations configured to accommodate additional magnetic or non-magnetic components.

9. The magnet array holder of claim 8, wherein each location in the set of additional locations includes markings indicating the orientation of the magnet piece to assist in aligning the additional magnet piece.

10. The magnet array holder of claim 1, wherein at least one slot in the set of slots extends through the magnet array holder.

11. The magnet array holder of claim 1, wherein the magnet array holder holds both magnetic pieces and non-magnetic pieces. 12 . The magnet array holder according to claim 1 , wherein the magnet array holder holds only magnet pieces.

13. The magnet array holder of claim 1, wherein the magnet array holder holds only a portion of an interaction loop of the vacuum electron device.

14. A method of assembling a magnet array configured to manipulate one or more electron beams in a vacuum electron device, the method comprising: A magnet array holder is provided, the magnet array holder being configured to hold magnet pieces and / or non-magnet pieces, the magnet array holder comprising: a set of slots configured to receive magnet pieces and / or non-magnet pieces; a set of recesses for receiving magnet pieces and / or non-magnet pieces; and one or more attachment interfaces configured to couple to a vacuum electronic device; positioning at least one pair of magnetic or non-magnetic members within the set of slots adjacent to particular recesses in the set of recesses; and A specific magnet piece is positioned within the specific recess of the set of recesses, and the pair of magnet pieces or non-magnet pieces serve as walls to support insertion of the specific magnet piece.

15. The method of claim 14, wherein each recess in the set of recesses has a bridge across it.

16. The method of claim 14, wherein each slot in the set of slots is configured to receive a respective non-magnetic member.

17. The method of claim 14, wherein each slot in the set of slots is configured to accommodate a magnet piece having an up / down polarization orientation.

18. The method of claim 14, wherein positioning the particular magnet member within the particular recess comprises orienting its polarity according to indicia.

19. The method of claim 14, wherein the magnet array holder further comprises a set of additional locations configured to accommodate additional magnet pieces and / or non-magnetic pieces; and the method further comprises positioning additional magnet pieces within the additional locations.

20. The method of claim 19, wherein positioning the additional magnetic and / or non-magnetic pieces comprises orienting polarity according to markings.

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