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Precision Collar and Yoke Lamination production techniques for prototype and series manufacture. . CERN 4 th /5 th December 2012 Todays speaker Paul Allen. Your text here. 1. Company Profile. Founded in 1968 Accredited to ISO 9001-2008 working towards ISO 14001 &

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  1. Precision Collar and Yoke Lamination production techniques for prototype and series manufacture. CERN 4th/5th December 2012 Todays speaker Paul Allen Your text here 1

  2. CompanyProfile • Founded in 1968 • Accredited to ISO 9001-2008 • working towards ISO 14001 & • OHSAS 18001 • Capabilities include • Toolmaking • Metal Pressings • Sub- assemblies • Electroplating • CNC Wire Erosion • CNC Machining • Busbar Manufacture • Laser Cutting • Employ 120 staff • €15 million sales turnover Company registration 00921793 2

  3. Quadrupole Magnet Assembly • MQXC Quadrupole Magnet Assembly • Weighs 1 Tonne • 2 metres high • 550mm diameter • Assembly took place at CERN 3

  4. Individual Yoke, Yoke stack and Yoke assembly • Material- Hot rolled steel • Component- individual yoke • Process- Laser cut and wire eroded • 340 yokes per assembly • Each yoke is 550mm in diameter • 5.2mm thick • Wire eroded within a 20 micron tolerance • Yoke stack showing, collar assembly • Yoke assembly top plate showing superconductors 4

  5. Collars • Material- 3mm stainless steel • Components- collars and fillers • Process- collars are Laser cut and Wire cut • Filler dimples are Pressed • 2 collars and 2 fillers make a complete 260 mm diameter collar assembly 5

  6. Stainless steel laser cut strips • Material- stainless steel • 2.5m dia master coil • Process- • Straighten/Roll • Crop • Laser cut 6

  7. Wire Erosion Department We have the latest wire erosion technology. Laser cut collars are wire cut finished to achieve sub 10 micron accuracy. 7

  8. Inspection – RAL & CMM • Typical inspection with the CMM • H.V.Wooding and CERN staff comparing notes • Independent inspection at Rutherford Appleton Laboratories • Expanded section view of collar wire cut within 10 micron tolerance 8

  9. Collar Assembly • Collar Assembly • Keyways aligned in a press • Fitted Superconductors visible • Full compliment Collar assembly on its rig • This is inside the CERN workshop • Complete assembly of Collars and Fillers 9

  10. CERN Projects Further applications for CERN. 10

  11. Wire Cut & Pressed Laminations • Material- Pre-bonded electric steel • Components- wire cut and pressed Laminations. • The wire cut lamination general tolerance20 microns we achieved 4 microns • 1000 laminations per stack • Compound press tool • Used 0.3mm x 150mm x 400mm electric steel • Welded assembly of RCS lamination stack 11

  12. Brookhaven • Material- low carbon steel 6.35mm thick, • Component- Dipole yoke collaring lamination • Process- Laser & Wire cut lamination • Full collar diameter 260mm • Material- steel 180mm thick x 700mm diameter weighing 250 KG • Component- HTS Quadrupole yoke • Process- Fully wire cut • Note the two 5mm x 30mm slots all the way • through • Built into a 6 segment assembly at Brookhaven 12

  13. 11 Tesla Dipole Project • Material-Low carbon steel & stainless steel • Components- collars and yokes • Processes- Laser cutting, CNC machining and Wire cutting • Dowel pin insertion • Tolerances of 7 microns in key areas 13

  14. Finally, thank you very much for taking the time to listen today, it was a real honour for us to be invited to talk. If you have any questions please do not hesitate to ask, we will be here for a short while and we also have an exhibition stand so feel free to pop by over the next two days. Once again, thank you for listening. Please visit our website on www.hvwooding.co.uk 14

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