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Winding and tooling tests Insulation choice. F.Rondeaux. Outline. Tests : First winding tests (March – April 2010) Winding tests still to be done Mechanical tests on stacks Conductor behaviour during heat treatment Insulation Specifications Conductor insulation. Tests.

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Winding and tooling tests insulation choice

Winding and tooling testsInsulation choice

F.Rondeaux

Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux


Outline
Outline

  • Tests :

    • First winding tests (March – April 2010)

    • Winding tests still to be done

    • Mechanical tests on stacks

    • Conductor behaviour during heat treatment

  • Insulation

    • Specifications

    • Conductor insulation

Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux


Tests
Tests

There is a list of questions we have to answer to be able to built the coil.

The aim of the test program is to allow us to have these answers.

Coil design

  • Tooling design

  • Winding

  • Heat treatment

  • Impregnation

Validation of parameters

- Materials parameters

- Insulation thickness

- …

Geometry, dimensions of the moulds…?

Verify feasibility

 Winding tests

Tests

Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux


First winding tests march april 2010 1 4
First winding tests (March – April 2010) 1/4

  • Q: how to wind the coil in the block design configuration(cf. II-4) with the design cable (cf.II-2)?

  • Q: what geometry for the ends?

  • bending tests have been performed :

    • bare copper cable

      • HFM dimensions

      • up to 10 turns.

    • dedicated tooling with modularity

      • variable ramp angle

      • versatile HW-bend geometry

      • 3 options for the end

Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux


First winding tests tooling 2 4
First winding tests – tooling 2/4

Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux


First bending tests results 3 4
First bending tests – results 3/4

  • A tension of 30 daNhas been considered as the best compromise in terms of cable behavior.

  • The circular end (which shows simplest geometry and saves conductor in comparison with ellipse and superellipse end options) is retained.

Close‐up on the hard‐way bend zone after several turns

Bending test tooling (final configuration)

Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux


First winding tests results 4 4
First winding tests – results 4/4

  • The flared configuration has been shown to be possible with the angle of 25° (considered as the largest reasonable value, and also the most critical in terms of bending radius): the cable is mechanically stable and a good quality winding has been achieved.

  • Additional tests with other parameters (angle = 15°, opposite winding direction) have confirmed the result.

R = 500 mm

Profile obtained with the natural curvature of the cable (positions of the rolls)

Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux


Winding tests still to be done
Winding 4/4 tests still to bedone

  • Winding test with returned ends (dummy cable)

  • Coil self supported

  • OK for the 2nd layer

  • Simplify the tooling

  • Avoid friction tape / rolls

  • Validation of the winding options with the actual insulated cable.

  • Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux


    Mechanical tests on stacks
    Mechanical tests on stacks 4/4

    • Q: validate the hypothesis on properties of the materials used for the model.

    • Q: define the size to be imposed on the coil during the heat treatment and the impregnation.

    • Avoid over stress during the manufacturing steps.

    • Dimensioning the sections of reaction mould / impregnation mould.

    • Dimensions used in modeling (at low temp. under stress) ↔ dimensions required for tooling.

    • Tests on stacks

      • Modularity of the test setup (≠ heights, …)

      • Compression at 300 K, at 4K

      • Thermal restraint

    Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux


    Conductor behavior during heat treatment 1 2
    Conductor behavior during heat treatment 1/2 4/4

    • Q : How to manage the behavior of the cable during the heat treatment?

      • Stress relief, increase of volume during the Nb3Sn formation, thermal expansion...

      • Influence of manufacturing process, composition and structure of filaments and strands

        Tests to be performed on the 2 types of conductor (PIT, IT)

      • How can we observe / quantify the deformation?

      • Structure of the mould? Ends fixed?

      • Compression on the cable?

         Need to define the experimental protocol

    Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux


    Conductor behavior during heat treatment 2 2
    Conductor behavior during heat treatment 2/2 4/4

    • Potential configurations for heat treatment tests on cable :

      • Length of cable free (1 m)

      • Length of cable in a mould with ≠ fixation points

      • Length of cable following the end geometry + half of the strait section

      • …?

      • Final test : full scale mock-up with 5 insulated turns

    Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux


    Insulation
    Insulation 4/4

    • Based on NED developments.

    • Mechanical requirements : support 150 MPa in compression.

    • Electrical requirements : maximum service voltage = 1000V

       Dielectric tests on the chosen materials

    • Thermal properties and radiation resistance are not an issue for FRESCA II coil.

    • Specifications (conductor insulation):

      • Insulation thickness : 150-200 µm per conductor face

        • Q: How to qualify/verify the thickness of tapes?

      • Insulation type : S-glass fiber + epoxy resin

    • Need of

      • Insulation between layers

         compatibility with impregnation process requirement

      • ground insulation

    Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux


    Conductor insulation
    Conductor 4/4insulation

    • Insulation type : glass fiber + epoxy resin

      • S2 glass tape desized

        • Tape (#416 from JPS) currentlyused for the SMC not completely satisfactory.

        • Hiltex S2 tape used at CEA no more available.

           Find new solution

          • Sleeve from Berkeley?

          • Braid S-glass tape directly on the conductor?

            • RAL will check if it is possible

          • New tape (S2, Hiltex ALF boron free alumina-silica fiber tape …)?

      • Vacuum impregnation

        • with epoxy resin (RAL, LARP …) ?

          (baseline = RAL#71A , 100 p. DGEBA MY750 + 55p. POPDA HY5922, Hunstman)

        • with cyanate ester / epoxy blend (chosen by ITER for radiation hardness)?

    • Insulation and impregnation will be tested on an SMC.

    Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux


    Conclusion
    Conclusion 4/4

    • Good quality winding can be achieved in the design geometry.

    • Next steps:

      • Winding test with returned ends (dummy cable + actual insulated cable): tooling under study.

      • Mechanical tests on stacks : to be defined.

        • validate the parameters used for the design studies

        • dimension the moulds

      • Management of the conductor behavior of the conductor during the heat treatment: study starting.

      • Choice of the insulation : search of solution under way.

    • The detailed program is under construction.

      Thanks for your attention

    Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux


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