Coil End Design Winding Test and End Parts

Coil End Design, Winding Test and End Parts Fabrication Susana Izquierdo Bermudez 2 nd Joint Hi. Lumi LHC/LARP Annual Meeting 15/11/2011

Coil Ends Design Strategy LARP CERN Define a set of common parameters Design of coils ends using BEND Design of coil ends using ROXIE Tests Exchange the set of designed spacers Tests Converge to an unique geometry Production of a unique set of end spacers 2

Common parameters • • • Cable dimension Cross Section Number of Blocks on the coil ends Number of Turns per Block z-position of the first cable on each block, total length of the ends and min. length of the spacers z 4 z 3 z 2 z 1 dmin Ltotal • Geometry of the layer jump 3

Coil Ends Design @ CERN 1 st approach (as HQ): z-position of the blocks optimized to min. peak field and opt. harmonics Block 4 (not much more than 10 turns per block) Block 3 Block 4. a Block 4. b Block 2. b Block 1 15. 00 14. 00 13. 00 Peak field in the block (T) 2 nd approach: Redistribute the conductors in three blocks per layer Block 3 Block 2 12. 00 Based on CERN Xsec ROXIE Block 2. a Block 1 12. 00 11. 00 10. 00 9. 00 8. 00 7. 00 0. 00 50. 00 100. 00 150. 00 Arc length of first strand in the block (mm) Block 1 Block 2 Block 3 Block 4 200. 00 7. 00 0. 00 Block 1 50. 00 100. 00 150. 00 Arc length of the first strand in the block (mm) Block 2. a Block 2. b Block 3 Block 4. a 200. 00 4 Block 4. b

Reproduction of a geometry defined by BEND in ROXIE A-length For a given A-length and winding angle, very close geometries can be found for the “male” surface of the spacer. 0. 3 mm 5

Winding Test AIM: Determine the mechanical stability of the cable • • Based on MQXF 3_v 0 Cross-Section. Return End + Lead End pole pieces, inner layer. 3 D Plastic printer. Winding mandrel in Aluminium. ESTIMATED DATE FOR FIRST WINDING TEST AT CERN: END-NOVEMBER 2012 (depending on cable availability) 6

End Parts Fabrication Parts Manufacturing method Winding tests & First Copper coil Plastic rapid prototyping Manufacturing time < 3 weeks Practice coils & First coils with Stainless Steel Laser Sintering 3 weeks Final parts Machining 3 months Insulation: Plasma coating + layer of fibre glass. 11 T, J. Mazet 7

Additional slides

Constant perimeter vs. Bend Differential Geometry Ends vs. Bend 10