LHQ Coil Design and Features Miao Yu Fermilab
LHQ Coil Design and Features Miao Yu Fermilab May 09, 2012
Overview • Plasma coating • • Instrumentation pockets in L 2 Pole gap Pole alignment Pin the L 1/L 2 poles Screw the poles to the mandrel Lifting holes Wire strain relief holes in L 1 Coil end holes for mechanical structure • Cooling channel LARP CM 18/Hi. Lumi LHC meeting 2
LHQ Coil Design • LHQ coil end parts were modified from the latest HQ design 1. 7 mil was removed from the surface where the insulation is inserted. 2. 10 mil was removed from the surface where plasma coating is applied. • • • Add 7 center pole pieces The RE saddles and the LE spliceblks are 2” longer than HQ LHQ coil length: 131” (~3. 33 m) LARP CM 18/Hi. Lumi LHC meeting 3
S 2 Glass L 2 LE Saddle L 2 LE Spacer 1 Apply on all L 1/L 2 spacers Apply on L 1/L 2 LE Saddle Apply on L 1/L 2 RE Saddle • 7 mil S 2 glass is installed in between the cable and the end parts • Remove 7 mil material from the surfaces in orange LARP CM 18/Hi. Lumi LHC meeting 4
• • • Plasma coating Instrumentation pockets in L 2 Pole gap Pole alignment Pin the L 1/L 2 poles Screw the poles to the mandrel Lifting holes Wire strain relief holes in L 1 Coil end holes for mechanical structure Cooling channel LARP CM 18/Hi. Lumi LHC meeting 5
Plasma Coating • • • To increase the dielectric strength coil to parts & coil to ground Al 2 O 3 plasma coating, 10 mil +1/-1 mil (250 micron +25/-25 micron) thickness requirement In addition of 7 mil (178 micron) material removal for S 2 glass, 10 mil (250 micron) material is removed from the surfaces in red for plasma coating 1. Proper vendor for +1/-1 mil tolerance, especially for the pole pieces (field quality? ) 2. Proper way to plasma coat the LE ramp area. If tolerance within +1/-1 m, we could do L 1 and L 2 separately. LARP CM 18/Hi. Lumi LHC meeting 6
Plasma coating Test • The saddle was plasma coated using Al 2 O 3 (without bond coating) to test 1. Electrical hipot to >1000 V 2. Material Compatibility (HT at ~665 C in Argon) 3. Thermal Stability 4. Thickness (QA): 150 micron +75/-75 micron (6 mil +3/-3 mil) 5. Metallography 6. HQ coil fabrication • Sample coupons (2” square, 1/8” thickness) – Ti 6 Al 4 V, SS 304, SS 316 Dan Cheng, LBNL LARP CM 18/Hi. Lumi LHC meeting 7
• • • Plasma coating Instrumentation pockets in L 2 Pole gap Pole alignment Pin the L 1/L 2 poles Screw the poles to the mandrel Lifting holes Wire strain relief holes in L 1 Coil end holes for mechanical structure Cooling channel LARP CM 18/Hi. Lumi LHC meeting 8
Pockets for wires • Protect the wire using shrinkage tube from the edge (wire short to shoe in LQ) • Maximum wire diameter: 2. 89 mm (not considering the thickness of the shrinkage tube LARP CM 18/Hi. Lumi LHC meeting 9
• • • Plasma coating Instrumentation pockets in L 2 Pole gap Pole alignment Pin the L 1/L 2 poles Screw the poles to the mandrel Lifting holes Wire strain relief holes in L 1 Coil end holes for mechanical structure Cooling channel LARP CM 18/Hi. Lumi LHC meeting 10
Pole gap • Pole gap is required during coil winding, because during reaction the cable needs room for thermal expansion. • The size of the gap is mainly depended on the cable parameters, coil length and winding tension. Winding isle bar Shim In HQ, Coil length: 1168. 4 mm Winding tension: 20 ~ 25 lbs (89~111 Newton) One gap: 0. 125 inch (3. 175 mm) ~ 2. 7 mm/m In LHQ, Coil length: 3327. 4 mm Winding tension: 35 lbs (156 Newton) Minimum total gap: 0. 63 inch (16 mm) ~ 2. 7 mm/m For practice coil 1 & 2: 0. 944 inch (24 mm) ~ 7. 2 mm/m Total 8 gaps, each gap is 0. 118 inch (3 mm) LARP CM 18/Hi. Lumi LHC meeting 11
• • • Plasma coating Instrumentation pockets in L 2 Pole gap Pole alignment Pin the L 1/L 2 poles Screw the poles to the mandrel Lifting holes Wire strain relief holes in L 1 Coil end holes for mechanical structure Cooling channel LARP CM 18/Hi. Lumi LHC meeting 12
Pin stud and notch • Align the pole during winding LARP CM 18/Hi. Lumi LHC meeting 13
Curing • Curing alignment key bars screwed to the pole through the lifting holes LARP CM 18/Hi. Lumi LHC meeting 14
R/I fixture φ0. 375” pin Reaction Fixture Impregnation Fixture • 6 alignment pins, 21. 34” apart ( 106. 7” ) to the slot of L 2 poles • Add shoulder to alignment pin to control insertion depth, separate set screw to secure pin. Jesse Schmalzle, BNL LARP CM 18/Hi. Lumi LHC meeting 15
Coils Assembly and Alignment Keys Coil & heater Collars Shlomo Caspi, LBNL LARP CM 18/Hi. Lumi LHC meeting 16
• • • Plasma coating Instrumentation pockets in L 2 Pole gap Pole alignment Pin the L 1/L 2 poles Screw the poles to the mandrel Lifting holes Wire strain relief holes in L 1 Coil end holes for mechanical structure Cooling channel LARP CM 18/Hi. Lumi LHC meeting 17
Pin and screw holes • Typical features for TQ/LQ/HQ/LHQ • The pins will be kept in the poles during curing, reaction and impregnation. • Screws will be removed from the poles after curing process. LARP CM 18/Hi. Lumi LHC meeting 18
• • • Plasma coating Instrumentation pockets in L 2 Pole gap Pole alignment Pin the L 1/L 2 poles Screw the poles to the mandrel Lifting holes Wire strain relief holes in L 1 Coil end holes for mechanical structure Cooling channel LARP CM 18/Hi. Lumi LHC meeting 19
Lifting holes Filled with RTV during Impregnation LARP CM 18/Hi. Lumi LHC meeting 20
• • • Plasma coating Instrumentation pockets in L 2 Pole gap Pole alignment Pin the L 1/L 2 poles Screw the poles to the mandrel Lifting holes Wire strain relief holes in L 1 Coil end holes for mechanical structure Cooling channel LARP CM 18/Hi. Lumi LHC meeting 21
#10 -24 tapped holes Filled with RTV during Impregnation For wire strain relief For mechanical Structure L 1 LE Spliceblk L 1 RE Saddle L 2 LE Spliceblk & L 2 RE Saddle have the same holes for mechanical structure LARP CM 18/Hi. Lumi LHC meeting 22
• • • Plasma coating Instrumentation pockets in L 2 Pole gap Pole alignment Pin the L 1/L 2 poles Screw the poles to the mandrel Lifting holes Wire strain relief holes in L 1 Coil end holes for mechanical structure Cooling channel LARP CM 18/Hi. Lumi LHC meeting 23
Cooling channel • Add cooling path in the pole pieces 4% open pole • In HQ/LHQ, the existing designed holes (for winding and lifting purpose) can be used as the cooling channel to demonstrate the technology (no coil to ground short) LARP CM 18/Hi. Lumi LHC meeting Giorgio Ambrosio, FNAL 24
Path along the radial direction G 10 key Jesse Schmalzle, BNL LARP CM 18/Hi. Lumi LHC meeting 25
LHQ RE ARE =9568. 17 mm 2 RE Ahole δ = Ahole/ARE Φ 8. 73 Φ 6. 73 59. 87 35. 57 0. 62% 0. 37% Φ 6. 73 Φ 5. 11 Φ 6. 73 20. 47 0. 37% 0. 21% in mm 0. 21% LARP CM 18/Hi. Lumi LHC meeting 0. 37% 2 Σδ = 2. 52% 26
LHQ Middle long keys: 6 pairs A =7054. 51 mm 2 δ = Ahole/A Φ 6. 73 0. 45% Φ 5. 11 0. 29% Φ 5. 11 Φ 6. 73 0. 29% LARP CM 18/Hi. Lumi LHC meeting 0. 45% Φ 6. 73 0. 45% in mm Σδ = 2. 38% 27
LHQ Middle short keys: 1 pair A =5284. 30 mm 2 δ = Ahole/A Φ 6. 73 Φ 5. 11 0. 6% 0. 39% Φ 6. 73 0. 6% Φ 6. 73 in mm 0. 6% Σδ = 3. 18% LARP CM 18/Hi. Lumi LHC meeting 28
LHQ LE ALE =9190. 81 mm 2 δ = Ahole/ALE Φ 6. 73 Φ 5. 11 Φ 6. 73 0. 39% 0. 22% 0. 39% Φ 6. 73 0. 39% Φ 8. 73 in mm 0. 65% Σδ = 2. 65% RE Pole 1 Cooling Rate Pole 1 Pole 2 Pole 1 2. 52 % 2. 38% LARP 3. 18% CM 18/Hi. Lumi 2. 38% LHC meeting 2. 38% LE Pole 29 2. 65%
HQ ALE =9190. 81 mm 2 ARE =9568. 17 mm 2 Φ 6. 73 δ = Ahole/ARE 0. 37% x 4 = 1. 48% Φ 6. 73 δ = Ahole/ALE 0. 39% x 4 = 1. 56% LARP CM 18/Hi. Lumi LHC meeting 30
Summary • 250 micron Al 2 O 3 will be plasma coated to the coil parts, and investment on the coating properties and thermal cycle stability is still going on through BNL and FNAL. • Large pole gap will be applied for practice coil 1 and 2, and be adjusted afterwards. • Cooling path is added to demonstrate the technology in HQ/LHQ LARP CM 18/Hi. Lumi LHC meeting 31
- Slides: 31
