Modular Coil R&D Keystone Activities

Modular Coil R&D Keystone Activities April 30, 2003 James H. Chrzanowski Mod Coil R&D Update

Keystone Trials- • The Keystone winding trials have begun. • Initial measurement of winding surface was performed using “Faro” measuring arm. • Bench top tests were performed Mod Coil R&D Update

FARO Arm Measurements • Plot from Faro arm measurements • Have not compared with original Pro-E model Mod Coil R&D Update

Keystone Bench Top Tests • Bench top tests were performed comparing the single copper conductor vs. 4-rope conductor • Lengths of insulated [1 half lapped layer of dry glass only] copper rope specimens were wound onto a 3.5 inch diameter pipe Mod Coil R&D Update

Prior to Winding After Winding 0.660 0.690 0.650 D A C 0.660 Height 0.545 Width 0.520 B Width Height Single Conductor- Results of Bench Top Tests A D C B Mod Coil R&D Update

Prior to Winding After Winding 0.750 Width 0.543 0.670 B Height D C 0.540 0.620 0.577 A Width A Height C D B 4-Rope Conductor- Results of Bench Top Tests Mod Coil R&D Update

Position 1 2 3 4 5 6 A .550 .533 .530 .540 .540 .545 B .640 .636 .630 .620 .645 .645 C .572 .597 .596 .577 .612 .610 D .723 .770 .770 .750 .740 .685 Position 5 10 15 20 25 30 35 40 Width .543 .540 .543 .540 .543 .543 .543 .543 Height .670 .670 .670 .668 .670 .670 .670 .670 4- Rope Conductor Prior to Winding After Winding Mod Coil R&D Update

Keystone Trials - 4 Rope Conductor • Extreme distortion and twisting of the individual copper ropes Mod Coil R&D Update

Additional Issues • Insulating the 4-rope conductor via the taping machine is extremely difficult • Twisting and separation of the ropes causes inconsistent application of insulation • The single conductor offers less of a challenge Mod Coil R&D Update

Keystone Trials- • Forward progress was needed • Decision was made to use our remaining 20 feet of single conductor to gain some preliminary Keystone data • Single copper conductor was hand insulated with glass and Kapton, positioned onto the winding form and clamped in place Mod Coil R&D Update

Preliminary Keystone data One observation made is that varying the clamp pressure can result in a ~0.008" change in the measurement. Mod Coil R&D Update

Keystone Fixture Locations Mod Coil R&D Update

Preliminary Findings- • Preliminary Keystone R&D activities have shown that the single conductor has many advantages over the 4-rope conductor. • It was hoped that the 4-rope conductor would reduce keystoning. In fact the opposite is true. • The conductors cannot slide to each other without causing extreme distortion. • Using an automatic taping machine on the 4-rope conductor is a nightmare. Inconsistent layers plus loose conductors are all counterproductive Mod Coil R&D Update

Conductor Recommendation • Seriously consider returning to single conductor as baseline plan for modular coils perhaps 34 ga instead of 36 ga • Procure additional single copper rope conductor for completing the Keystone tests (Carm Hjelm from New England wire will have a quote to me by tomorrow. He expects delivery by approx. June 6th.) • Use the 4-rope conductor for winding the demo(racetrack) coil • Hand insulate if necessary • Use the 4-rope conductor for balance of specimens for CTD mechanical thermal tests. • Prepare several single conductor specimens for comparison with 4-conductor test results • Use single conductor for next major VPI of twisted tee Mod Coil R&D Update

Modular Coil R&D Keystone Activities