Magnet Spacers Design Automation

1. Roxie2Catia Catia Forum – Sept. 29th Magnet Spacers Design Automation

2. Roxie2Catia Magnet Spacers Design Automation Summary • What is a Magnet Spacer? • Process • The Roxie2Catia tool • Result • Improvements

3. Roxie2Catia Magnet Spacers Design Automation What is a Magnet Spacer? • In a dipole, the spacers are here to guide and separate the different layers of a coil. • It's a set of parts with a very specific shape. • The basic shape is a cylinder, which is split by many ruled surfaces. • The purpose is to make sure that the coil's winding is perfect, a pre-requirement for a good quality magnetic field.

4. Roxie2Catia Magnet Spacers Design Automation The Process • Define the design of each part. • -> ROXIE application • Build the shapes with a CAD software. • -> ROXIE2CATIA tool • Manufacturing prototypes. • After prototypes validation, production.

5. ROXIE (Routine for the Optimization of coil X-sections, Inverse computation, and End design) • ROXIE is a software for • the electromagnetic design and simulation of accelerator magnets. • Key features (not available in commercial products) • 2D coil design • 3D coil end design • FE-BE coupling • superconductor effects • quench simulation. • All superconducting LHC magnets designed with ROXIE. • Licenses are sold via Technology Transfer to all major accelerator-technology labs.

6. ROXIE in Accelerator Magnet Design Multipole Variation EM Forces Cable Data (Input) Coil Variants Yoke Simulation Quench Margins Mechanical End Design Magnetic End Design Persistent Currents Fixing the Cross-Section Production Follow-Up Endspacers: Catia and CAD/CAM Interface Quench Simulation Determine Yoke Cutback & Operations Trouble-Shooting

7. Roxie2Catia Magnet Spacers Design Automation The Roxie2Catia tool • Purpose: • As a result, Roxie provides a text file, with points coordinates. • The Roxie2Catia tool as been made to help the designer to build a magnet spacer set from these points. • The main steps to do this are explained in the following slides.

8. Roxie2Catia Magnet Spacers Design Automation The Roxie2Catia tool • Main features: • This tool is an expert tool. • > Skills in GSD & knowledge workbenches are necessary. • > The tool is available on the network. • > There is one dedicated user trained to use it. • > 3 icons can be created in Catia V5 (personal settings) to launch the different functions. • Help / Guide • Export as Step • Run the Roxie2Catia Tool

9. Roxie2Catia Magnet Spacers Design Automation The Roxie2Catia tool • Inputs: • > Text file with points coordinates • Each group of points corresponds to the definition to an half-edge.

10. Roxie2Catia Magnet Spacers Design Automation The Roxie2Catia tool • 1st step: • > Sort these groups of points, to put together the points that define a surface : • 4 groups for the 2 end shapes • 8 groups for the others • The points are temporally stored and sorted in Excel.

11. Roxie2Catia Magnet Spacers Design Automation The Roxie2Catia tool • 2nd step: • > Importing these points to Catia in a new Part

12. Roxie2Catia Magnet Spacers Design Automation The Roxie2Catia tool • 3rd step: • > Build the cylinder based on these points

13. Roxie2Catia Magnet Spacers Design Automation The Roxie2Catia tool • 4th step: • > Creating the rules on each couple of points. • Each point is projected on the cylinder internal or external surface. • Then the rules (lines) are created.

14. Roxie2Catia Magnet Spacers Design Automation The Roxie2Catia tool • 5th step: • > Creating the ruled surfaces that rely on the sets of rules. • Each surface should have a continuity in tangency, and a null Surface Curvature. The surfaces are extrapolated to make sure that it will be possible to split the cylinder later.

15. Roxie2Catia Magnet Spacers Design Automation The Roxie2Catia tool • 6th step: • > Splitting the cylinder to create the spacers.

16. Roxie2Catia Magnet Spacers Design Automation The Roxie2Catia tool • Result: • > Splitting the cylinder to create the spacers. The final result is a fully parametric Part. The user can modify the geometry as whished, if necessary.

17. Roxie2Catia Magnet Spacers Design Automation Result After the spacers have been created, we have to ensure that the spacersand the coils are fully compatible. Some additional features have also to be manually added. Then the prototypes can be manufactured.

18. Roxie2Catia Magnet Spacers Design Automation Result If the result has to be shared with others institutes that don't use Catia V5, an export function can generate a set of Step files. Each shape is saved as a step.

19. Roxie2Catia Magnet Spacers Design Automation Improvements At this time, the Roxie2Catia tool manage to realize spacers, even if sometimes the user has to perform manual updates. The Macro doesn't generate the coils. The users have to use the VRML (*.WRL) files provided by Roxie. It is not a blocking point, but native Catia V5 coils could ease the drafting and save time to store the coils in SmarTeam. The interface has to be improved to be more user-friendly, and a guide has to be written.

20. Roxie2Catia Magnet Spacers Design Automation Thanks for your attention. Special thanks to Ludovic F. & Bernhard A. for the explanations and pictures.