EuCARD-WP7-HFM ESAC Review of the dipole design Engineering Design
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Transcript of EuCARD-WP7-HFM ESAC Review of the dipole design Engineering Design
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EuCARD-WP7-HFMESAC Review of the dipole design
Engineering Design
Pierre MANILCEA/iRFU/SIS
January 20, 2011 @ Saclay
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Contents
• Inputs
• Magnet detailed geometry► Overview► Ends► Layer jump► Cable needs
• Structure detailed geometry► Overview► Focus► Masses
• Detailed engineering► Materials choice► Tolerances and machining
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• Magnetic inputs [1]► Cable properties► 2D magnetic layout
• Mechanical inputs [1]► 2D stress analyze► 3D conceptual study
• Constraints [2]► Specified straight section > 700 mm
Source: FRESCA2 test station requirements► Overall magnet length = 1500 mm
Source: EuCARD contract► Specified aperture = Φ100 mm
Source: EuCARD contract► Reaction furnace section = 350 x 200 mm
Inputs
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Magnet detailed geometry
[Draftsman: Jean-François Millot]
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Overview
• 1.5 m – long• Straight section length > 700 mm
✓
✓
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Preliminary test
• HW-bend is OK with this cable [3]• Ramp angle up to 25° possible• HW ‘safe radius’ ~ 500 mm• Circular end is OK• See Françoise’s talk
~R500
• Bare copper cable, HFM dimensions • Variable ramp angle• Versatile HW-bend geometry• 3 options for the end
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4 • Geometrical definition of the ends [2]► R > 500 mm (test)► Lss > 700 mm► Los > 0► htot < 200 mm► aperture 61 mm
Ends
α = 17°, R varies R = 700 mm, α varies
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• 17° ramp, R = 700 mm => Los = 24 mm, Lss = 730 mm (layer jump included) • Can be compared to HD2 [4]: 10° ramp, R ~ 350 mm• Slight differences between lead/return end
Ends details
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4 • Several options have been considered [5]
• ‘HW soft’ is selected
Layer jump
42423636
42423636
43423635(flat)
✓
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Layer jump details
Straight section(= 700 mm)
‘Chicane’in the top layer(over 28 mm)
HW-bend connection(in a plane)
to the bottom layer
Layer jump 3-4 [CATIA drawing]
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24 • ~ 1 km of cable for the dipole• ~ 50 km of strand
Cable needs
CABLE NEEDS
Sub-elementTheoretical
cable length (m)
+ 3% margin
Double-pancake 1-2 223 230
Double-pancake 3-4 253 260
1 POLE 476 490
FULL DIPOLE 952 981
in onepiece
4 pieces of cable
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• Shell-based structure principle from Berkeley [6]• Additional calculations are still needed• Connections (out of the structure) to be designed• Assembly process in Maria’s talk
Structure detailed geometry
[Draftsman: Pascal Labrune]
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Overview
Iron yoke
70 mm-thick aluminum shell
Axialpre-stress
system
COIL PACK
Coils 100 mm aperture(no bore tube)
Bladders and shims
Material colors:Coil Steel Aluminum Iron Titanium Aluminum-Bronze Insulation (Tooling)
1600 mm
2066 mm
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Focus: coil pack
Flexible insulation (~1 mm)
Vertical Pad171 iron laminations:MAGNETIL (LHC iron)
5.8 mm-thick
Horizontal Padin one steel piece
5 mm-thicksteel plates
No bore tubeRails, pole and
horseshoes potted with the coil
Steel wedges
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Focus: poles
Contactover 6 mm
Groove for midplane
shims
Layer jump template
Longitudinal positioning
notch
Vertical contacthere
Axial stop for midplane shim
500 MPaσeq peak@ 13 T
[1]
Titanium pole
Soft iron pole
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Focus: yoke
Notcheson both sides
for bladder positionning
Rod holes
Longitudinal Weld
Pinning holes x3
Yoke half250 iron laminations:MAGNETIL (LHC iron)
5.8 mm-thick
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Focus: axial compression system
Φ~30 mmaluminum rodsSteel end plates
(~100 mm)TO BE DIMENSIONNED
Hydraulic pre-stress tooling
of the SMC system [7]
Clearance for key insertion
Coil/Plate contact offsetwith grub screws
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Focus: bladders
• 14 bladders allowed [6]• 1.6 m-long (or 2 x 0.8 m-long)• Target pressure ~100 bars
Conical lock(700 bars)
Removable insertion shim
2 steel sheets (0.3 mm-thick)
Waterarrival
Laser-weld all along
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Focus: keys
• 6 keys• 1.6 m-long (or 2 x 0.8 m-long)• Versatile thickness (stack of shims)
Pin
Round chamfer all along
for insertion
Stack of shims(0 to 1000 μm)
Nominalsteel keys ‘sandwich’
(3+3 mm)
Handling hole
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24 • Magnet ~ 300 kg (copper density)• Structure ~ 10 300 kg (without magnet)
Masses
Sub-element Material Quantity Total mass (kg)
Double-pancake 1-2 Insulated Nb3Sn* 2 138
Double-pancake 3-4 Insulated Nb3Sn* 2 156
Lower pole Titanium 2 38
Upper pole Iron 2 57
Horseshoes Steel 4 36
Rails Al Bronze 4 94
Midplane shim Steel 2 21
Horizontal Pad Steel 2 640
Vertical Pad Iron + Steel 2 1047
Wedge Steel 2 152
Yoke Iron + Steel 2 6 950
Shell Aluminum 1 1 020
Axial rods Aluminum 4 21
End plates Steel 2 200
Keys Steel 6 27
TOTAL 10 597
Pottedpoles:519 kg Coil pack:
2 379 kg
* See Philippe’s talk
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Materials choice
Material Parts 2D peakstress R Properties [8]
MPa MPa
Nb3Sn with NED insulation Coil 142 [150]
Magnetic steel Top pole 345* > 600
MAGNETIL iron laminations Yoke / Y-Pad 410* > 600 5,8 mm-thick sheets available at CERN
Steel AISI 316L X-Pad / Y-Pad 315 490-690 Solderable, amagnetic,resistant to corrosion
Titanium Ti-6-Al-4V Bottom pole 500 900
Al 2014 T651 (A-U4 SG)Shell 205
435 Solderable, machinable,limited resistance to corrosion
Al 7075 T651 (A-Z5GU) 485 Machinable, limited resistance to corrosion,limited solderability
• 2D stresses are supported• 3D stresses to be checked
Peak stress values from Attilio Milanese [1]* = corner value
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24 • Mostly conventional shape tolerances• Refined tolerances on key insertion planes and
bladder notches
• Lamination machining process• Outer shell:
► Outer diameter φ1140 mm► Overall length = 1600 mm, can be divided in several parts► Influence of the cylindrical tolerance between shell and yoke?► Can we allow roll welding?
Tolerances and machining
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Thank you
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References
[1] Fresca2 conceptual designA. Milanesetalk given this morning
[2] EuCARD-HFM dipole specification and baseline parametersMPWGEuCARD-HFM internal note, January 2011
[3] EuCARD-HFM : Rapport sur les essais de cintrage des têtes de bobine en configuration blocF.Rondeaux, A. Przybylski, P.ManilCEA report, ref. SAFIRS 00152 A, June 2010
[4] Design of HD2: a 15 Tesla Nb3Sn Dipole with a 35 mm BoreG. Sabbi et al.IEEE Trans. Appl. Supercond., 2005
[5] 21-10-10 - Status of the turns-by-turns modelP. Manil, J.-F. MillotEuCARD-HFM internal note, October 2010
[6] The use of pressurized bladders for stress control of superconducting magnetsS. CaspiIEEE Trans. Applied Superconductivity, vol. 16, Part 2, pp. 358–361, June 2006
[7] Mechanical Design of the SMC (Short Model Coil) Dipole MagnetF. Regis et al.IEEE Trans. Appl. Supercond., Vol. 20, 2010
[8] NF E 01-000 and NF A 50-451