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LARP Collaboration Meeting TQS01 - Progress

LARP Collaboration Meeting TQS01 - Progress. Shlomo Caspi Lawrence Berkeley National Laboratory April 26-28, 2006. Outline. TQS01 - Construction Design and Analysis Preliminary test results. Statement of work – TQS01. One of the main objectives:

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LARP Collaboration Meeting TQS01 - Progress

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  1. LARP Collaboration Meeting TQS01 - Progress Shlomo Caspi Lawrence Berkeley National Laboratory April 26-28, 2006

  2. Outline • TQS01 - Construction • Design and Analysis • Preliminary test results S. Caspi

  3. Statement of work – TQS01 One of the main objectives: • Compare the magnet performance with the design parameters. S. Caspi

  4. TQS01 Main Features • A 2 layers Nb3Sn Quadrupole • A 10mm wide 27 strand cable. (0.7mm MJR strand) • Short sample 4.2K (B,G,I) : 11.2T, 220T/m, 12.3kA • Accumulated Lorentz stress : S_theta=-123MPa • Accumulated axial force (4 quadrants) : F_z=350kN S. Caspi

  5. Aluminum shell 4 pads Yoke Keys Filler Bladder 2 layers TQS01 The structure and assembly is different from any previous magnet of this kind • No collars • Bladders for coil azimuthal pre-stress • B ~ 12 T, stress: 150 MPa, total axial force = 350 kN S. Caspi

  6. TQS01 – Construction • Coil winding • Coil reaction • Instrumentation • Impregnation • Coil sub-assembly • Structure sub-assembly • Final assembly and pre-stress S. Caspi

  7. Coil winding at FNAL • A double layer • Bronze island and end spacers • Layer 1 wound on a mandrel and cured using a binder. • Layer 2 wound on top of layer 1 and then cured. S. Caspi

  8. Coils Shipped to LBNL S. Caspi

  9. Prepare for Reaction Two coils reacted together S. Caspi

  10. Into Reaction Oven S. Caspi

  11. Reaction Cycle (Coils 7 and 8) • 72 hr at 210 C • 48 hr at 400 C • 48 hr at 640 C S. Caspi

  12. Post-Reaction S. Caspi

  13. Strain gauge Voltage tap Inner layer trace Coil - Instrumentation Strain gauges and voltage tap attached to trace S. Caspi

  14. Ready for Impregnation S. Caspi

  15. Impregnation Coil placed into impregnationchamber Controller S. Caspi

  16. Impregnated Coils Strain gauges placed on layer 1 island Voltage traces S. Caspi

  17. Coil-pack sub-assembly Coil-pack is a sub-assembly of coils pads and fillers Coil Pack is assembled, squared and bolted. S. Caspi

  18. Structure sub-assembly, shell, yoke and intermediate gap keys • 20” OD x 18” ID x 40”long, 6061-T6 aluminum shell, precision machined. • 1018 steel yoke laminations, 2”-thick S. Caspi

  19. SHELL & YOKE SUB-ASSEMBLY,cont’d S. Caspi

  20. Final assembly • Mating the coil pack with the shell & yoke sub-assembly. S. Caspi

  21. bullets Strain gauges End plate (89 mm thick) Axial Aluminum rods (44 mm dia.) End Support S. Caspi

  22. End plates assembly S. Caspi

  23. Axial load components S. Caspi

  24. Axial Pre-stress S. Caspi

  25. Axial Pre-stress, cont’d • Axial Loading Rig • 25 -Ton hydraulic actuator (9500 psi) S. Caspi

  26. Azimuthal pre-stress (bladder operation) S. Caspi

  27. Complete assembly – return end S. Caspi

  28. End splices S. Caspi

  29. End splices (pizza box) S. Caspi

  30. TQS01 lowered into cryostate S. Caspi

  31. Outline • TQS01 – Construction • TQS01 – Design and Analysis • TQS01 – Peliminary results (cool-down) S. Caspi

  32. FEM structuremulti-physics Integrated analysis and simulations CAD (engineering) FEM (magnetic) S. Caspi

  33. ANSYS x, y, and z coordinates of each coil element center OPERA Computation of J x B (N/mm3) at each x, y, and z coordinate ANSYS Computation of J x B  Vel (N) Final force applied to each coil node 3D mechanical analysis: Lorentz forces S. Caspi

  34. I=13.5kA,1.9K Layer 2 |B|=12.0T END Layer 1 |B|=12.15T in SS TOSCA Maximum field: Layer 1 - straight section Layer 2 - end S. Caspi

  35. Structural Analysis - ANSYS Steps: Assembly. Cool-down. Lorentz forces 10-15 kA Load Cases: • Combinations of azimuthal and axial pre-stress • Model with and without friction or glued • Blocked turns and individual turns S. Caspi

  36. 2 3 1 ANSYS model – straight section Rule 1 - No azimuthalseparation at the pole S. Caspi

  37. Rule 2 - No axial separation in the end Island Spacer End-shoe ANSYS model – coil ends S. Caspi

  38. SS 1.8K SS 4.2K Structure – Shell - azimuthal Shell and yoke mu=0.6, all other surfaces with friction, mu=0.2 Low assembly pre-stress S. Caspi

  39. Structure – Axial rods Low assembly pre-stress S. Caspi

  40. Short sample 1.9K Short sample 4.2K ± range Azimuthal stress in layer 1 (with friction) 4.2 K 14kA S. Caspi

  41. Training Mechanism Straight section • Axial tensile strain in the pole island held by friction releases when the coil pulls away due to insufficient azimuthal pre-stress. End section • Sliding and tarring between the coil and the island due to insufficient axial pre-stress. S. Caspi

  42. abrupt or slow release of strain Island axial strain- straight section S. Caspi

  43. release of axial strain S. Caspi

  44. Ends and axial Lorentz Force Lorentz axial force 351/413 (kN) Applied axial force 800(kN) (with friction) S. Caspi

  45. 0 friction, limited axial load S. Caspi

  46. 170 µm Island axial displacements- end section Island displacement (with friction) S. Caspi

  47. Outline • TQS01 – Construction • TQS01 – Design and Analysis • TQS01 – Preliminary test results S. Caspi

  48. Strain Measurements S. Caspi

  49. Cool-down S. Caspi

  50. 4.3K 200K Rods – measured cool-down stress S. Caspi

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