11 tesla demonstrator dipole model design fabrication n.
Download
Skip this Video
Loading SlideShow in 5 Seconds..
11 Tesla Demonstrator Dipole Model Design & Fabrication PowerPoint Presentation
Download Presentation
11 Tesla Demonstrator Dipole Model Design & Fabrication

Loading in 2 Seconds...

play fullscreen
1 / 27

11 Tesla Demonstrator Dipole Model Design & Fabrication - PowerPoint PPT Presentation


  • 87 Views
  • Uploaded on

11 Tesla Demonstrator Dipole Model Design & Fabrication. Fred Nobrega, Fermilab 1 st FNAL-CERN Collaboration Meeting Fermilab, May 13, 2011. Demonstrator Dipole Cold Mass Parameters. Fiducial. Alignment Keys. Skin. Yoke. Clamp. Collar. Cold Mass Fabrication at FNAL.

loader
I am the owner, or an agent authorized to act on behalf of the owner, of the copyrighted work described.
capcha
Download Presentation

PowerPoint Slideshow about '11 Tesla Demonstrator Dipole Model Design & Fabrication' - toan


An Image/Link below is provided (as is) to download presentation

Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author.While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server.


- - - - - - - - - - - - - - - - - - - - - - - - - - E N D - - - - - - - - - - - - - - - - - - - - - - - - - -
Presentation Transcript
11 tesla demonstrator dipole model design fabrication

11 Tesla Demonstrator Dipole Model Design & Fabrication

Fred Nobrega, Fermilab

1st FNAL-CERN Collaboration Meeting Fermilab, May 13, 2011

demonstrator dipole cold mass parameters
Demonstrator Dipole Cold Mass Parameters

Fiducial

Alignment Keys

Skin

Yoke

Clamp

Collar

Demonstrator Dipole Cold Mass Fabrication

cold mass fabrication at fnal
Cold Mass Fabrication at FNAL

2m & 4m Dipole magnet w/ 50mm end plates

420 mm

Dipole collaring tooling used for dipole style collaring of a quadrupole magnet.

Demonstrator Dipole Cold Mass Fabrication

sample nb 3 sn coil travelers
Sample Nb3Sn Coil Travelers

Demonstrator Dipole Cold Mass Fabrication

winding curing reaction impregnation at fnal

6 m curing press

(LM, LQ)

2 m curing press

(DD, HFM, TQ )

1 m furnace (HFM, TQ)

6 m furnace

(LM, LQ)

Winding, Curing, Reaction, & Impregnation at FNAL

4 m wind table

(DD, LQ, HFM)

6 m Selva winder

(MQXB)

8 m impregnation oven

(HFM, TQ, LM, LQ)

handling
Handling

2m dipole clamped assembly

Cured 2m dipole coil transfer from winding mandrel to reaction tooling base plate.

coil shipping
Coil Shipping

Potted coil shipment to LBNL from FNAL.

11 Tesla plan includes coil and collar shipments to CERN.

  • Cured coil shipment to
  • BNL from FNAL.

Demonstrator Dipole Cold Mass Fabrication

demonstration dipole cable cable insulation
Demonstration Dipole Cable & Cable Insulation

Coil:

  • 2-layer shell-type
  • 56-turns, 21-Layer 1, 35-Layer 2
  • 3-layer 1 wedges
  • 1-layer 2 wedge
  • Alignment notch in L2 pole pieces

Cable:

  • Strand – RRP, 0.7 mm
  • Number of strands – 40,
  • Keystone angle – 0.79° *
  • Width – 14.7 mm *
  • Thickness – 1.269mm *

Insulation:

  • thickness – 0.150, 0.075 mm x 12.7 mm wide E-glass double butt lap *

* unreacted

Demonstrator Dipole Cold Mass Fabrication

Fred Nobrega 8

cable
Cable

Salient parameters of the Rutherford-type cable- illustration of the cable cross-section.

  • Nb3Sn strands expand due to the phase transformation ~ 3% in thickness & ~1% in width
  • Design of the coil winding and curing tooling is based on the cable cross-section prior to reaction.
  • Design of the coil-reaction and impregnation tooling are based on the reacted cable’s dimensions.
  • Reacted cable size used for the electromagnetic and structural analysis & optimization.

13 May 2011, FNAL-CERN CM1

Demonstrator Dipole Cold Mass Fabrication

Fred Nobrega 9

cable insulation
Cable Insulation
  • Insulation material E-Glass thickness – 0.150, 0.075 mm x 12.7 mm wide E-glass double butt lap

13 May 2011, FNAL-CERN CM1

Demonstrator Dipole Cold Mass Fabrication

Fred Nobrega 10

coil winding
Coil Winding
  • FNAL, BNL, & LBNL have successfully collaborated throughout the LARP coil fabrication process.
  • Inner and outer coils are wound without a splice between them.
  • Coil cables have anisotropic material properties.
    • Titanium pole pieces (slight coil tension at cool down)
    • Stainless steel wedges (less longitudinal shrinkage (better match with coil longitudinal CTE)
    • Stainless steel & Titanium end parts provided by CERN (lower CTE than Al Bronze)
  • Lessons learned have been incorporated into coil fabrication.
    • De-cabling during winding controlled withwinding techniques (reducing winding tension at critical moments)
    • Adding a 360° twist between the cable tensioner and the coil during winding
    • Changed cable tension system (cable now takes a straight path from the tensioner to the coil, rather than passing through a series of rollers)
    • Gaps between coil and end parts solved by cutting slots into certain end parts to make them more flexible.

Demonstrator Dipole Cold Mass Fabrication

coil curing
Coil Curing
  • After winding, cable insulation is injected with ceramic binder CTD-1008.
  • Coils are cured at 150° C for 30 minutes in a closed cavity mold.
  • Azimuthal coil pressure is approximately 27 MPa.
  • Purpose of curing is to set the coil size for reaction and for easy handling for into the reaction fixture without damage.

Demonstrator Dipole Cold Mass Fabrication

Fred Nobrega 12

11 tesla demo dipole copper coil winding
11 Tesla Demo Dipole Copper Coil Winding

Demonstrator Dipole Cold Mass Fabrication

cured coil transfer
Cured Coil Transfer

Demonstrator Dipole Cold Mass Fabrication

Fred Nobrega 14

coil reaction
Coil Reaction
  • Closed cavity mold defines the coil size precisely
  • Tooling is modular, the process can be easily adapted to long magnets

Process improvement:

  • Stopped using welded retort and use positive pressure in tooling.

Demonstrator Dipole Cold Mass Fabrication

Fred Nobrega 15

heat treatment cycle
Heat Treatment Cycle

Measurement

Program

Days

Demonstrator Dipole Cold Mass Fabrication

Fred Nobrega 16

cable power lead solder splices to coil
Cable Power Lead Solder Splices to Coil
  • After reaction, coil power lead splices are soldered within the same tooling that was used for reaction.
  • NbTi cable is used for the coil power leads & is the same width (14.85 mm) as the Nb3Sn coil cable.

Demonstrator Dipole Cold Mass Fabrication

Fred Nobrega 17

coil impregnation measurement

8 m impregnation oven

(HFM, TQ, LM, LQ)

Coil Impregnation & Measurement
  • Impregnation is with CTD101K and is done in the IB2 vacuum oven at 30-50 mm Hg with epoxy temperature of 60° C.
  • Curing is done in IB2 at 125° C for 21 hr.
  • After curing the strain gauges are added & quench heaters connected.
  • Coil inspection with Coordinate Measurement Machine (CMM)
  • Used for checking cross section uniformity and azimuthal size to help determine mid-plane shim for coil pre-load.

Demonstrator Dipole Cold Mass Fabrication

Fred Nobrega 18

ground insulation
Ground Insulation
  • Robust electrical ground insulation scheme
  • 5 layers of Kapton ground insulation with staggered gaps
  • Stainless steel quench heaters located between layers 2 & 3 from the coil

Demonstrator Dipole Cold Mass Fabrication

Fred Nobrega 19

coil assembly station
Coil Assembly Station

LHC MQXB coils during ground and coil assembly

Demonstrator Dipole Cold Mass Fabrication

Fred Nobrega 20

collaring
Collaring
  • The two coils, surrounded by ground insulation and collaring shoes (two metallic protection sheets)
  • Pre-assembled 50 mm collar lamination packs are placed around the coil assembly
  • Main press cylinders are energize to open keyway.
  • Keys are hydraulically pressed into the collars
  • Yoke laminations surround the collar assembly and held together with aluminum keys

Demonstrator Dipole Cold Mass Fabrication

Fred Nobrega 21

aluminum key insertion
Aluminum Key Insertion

Demonstrator Dipole Cold Mass Fabrication

shell welding preparation
Shell Welding Preparation

Demonstrator Dipole Cold Mass Fabrication

shell welding
Shell Welding
  • New redesigned weld carriages for improved welding reliability
  • Press used for welding the 2m and 4m HFM Nb3Sn dipole cold masses

Demonstrator Dipole Cold Mass Fabrication

Fred Nobrega 24

cold mass final assembly
Cold Mass Final Assembly
  • Add instrumented bullet pressure plates
  • Weld end plate to skin
  • Add strain gauges to skin
  • Final electrical and hi-pot test
  • 1
  • 2
  • 3
  • 4

Return end cross section: 1 – end plate; 2 – strain gauge bullets; 3 – bullet pressure plate; 4 – skin

Demonstrator Dipole Cold Mass Fabrication

Fred Nobrega 25

nomenclature
Nomenclature
  • For the 2 meter MODEL program (D)emonstrator (M)odel + a serial number:

DM-01 encompasses all of the processes to assemble finished coils into a magnet.DM-M-01 mirrorDM-CF-01 coil FermilabDM-CC-01 coil CERN

  • For the 5.5 meter PROTOTYPE program (D)emonstrator (P)rototype + a serial number:

DP-01 encompasses all of the processes to assemble finished coils into a magnet.DP-M-01 mirrorDP-CF-01 coil FermilabDP-CC-01 coil CERN

The "CF" and "CC" encompasses all of the processes for the coil and its cable.

Demonstrator Dipole Cold Mass Fabrication

conclusion
Conclusion
  • Established traveler and quality control system.
  • Established Nb3Sn coil fabrication technology based on long/short dipole cold masses and Nb3Sn collared cold masses.
  • Demonstrated a working collaboration between the 3 labs.
  • Successfully demonstrated:
    • winding & curing of 58 Nb3Sn coils
    • handling and shipment of coils
  • Demonstrated Fermi’s ability to successfully:
    • react & epoxy impregnate TQ,LM & LQ coils
    • fabricate long coils using established TQ HFM dipole coil fabrication technology

Demonstrator Dipole Cold Mass Fabrication