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Hardware Challenges and Limitations for the IR Upgrades Stephan Russenschuck

Hardware Challenges and Limitations for the IR Upgrades Stephan Russenschuck for the (EU) WP-5 and WP-6 teams [LHC IR Phase-I Upgrade WP-4, WP-5] MQXC, Cryostats, and Corrector package 28.01.2010. 1. Overview. Framework: EU-WP6 and White-Paper Deliverables and Milestones

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Hardware Challenges and Limitations for the IR Upgrades Stephan Russenschuck

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  1. Hardware Challenges and Limitations for the IR Upgrades Stephan Russenschuck for the (EU) WP-5 and WP-6 teams [LHC IR Phase-I Upgrade WP-4, WP-5] MQXC, Cryostats, and Corrector package 28.01.2010 1

  2. Overview • Framework: EU-WP6 and White-Paper • Deliverables and Milestones • Design and construction activities/challenges • Challenges (Heat load, powering and protection, axial forces, collaring) • New features (Porous cable and ground-plane insulation, tuning shims) • Integrated design process (quench simulation, end-spacer design) • Planning issues (How much R&D)

  3. Low-b Quadrupole MQXC Coil aperture 120 mm Gradient 127 T/m Operating temp 1.9 K Current 13.8 kA WP on load-line 85% Inductance 5.2 mH/m Yoke ID 260 mm Yoke OD 550 mm Magnetic length 9160 mm (Q1,Q3) 7760 mm (Q2) LHC cables 01 and 02 Porous cable polyimide insulation Yoke OD identical to MB Self-supporting collars Single piece yoke Welded-shell cold mass

  4. The EU and White-Paper Frameworks

  5. EU-FP7 and Accord-Technique (F)

  6. EU-FP7 and Accord-Technique (F)

  7. EU-FP7 and Accord-Technique (F)

  8. List of Components, Tooling, Assembly Activities, and Tests (MQXC)

  9. MQXA (KEK) 5 years 5 Models built (revision of inner layer)

  10. MQXB (Fermilab) 5 years 9 Models (change of cables)

  11. Can we do Better than 4-5 Years ? Pro Contra More advanced simulation tools Integrated design and manufacture for end-spacers Faster link between CAD and FE modeling More sophisticated CAD/CAM Existing specifications Cryostat identical to MB Cable available Large aperture EU-Industrial suppliers EU/White paper Technical experience In-house production Heat load (porous insulation; coil modulus) Busbar design and routing Horizontal collaring (new press to be procured) Magnet protection (nested PCs, heaters) Axial forces EU-Certification of tooling

  12. Heat-Load and Cooling Requirements

  13. Ferromagnetic Tuning Shims (Rods and Plates)

  14. Coil Layouts (4-Block / 6-Block) 12804 A, 79.6% on load-line (for 120 T/m) 12683 A, 78.45% on load-line

  15. Improved Heat-Extraction (1: Porous Cable Insulation) 50 µm

  16. Improved Heat-Extraction (2: Porous Ground-Plane Insulation) Conventional ground insulation Open ground insulation

  17. Quench Simulation (LHC MB)

  18. Magnet Protection Study (Dump Resistor and Heaters) 18

  19. Endspacer Design and Manufacture Differential Geometry Model Virtual Reality Preview Roxie-Catia Interface CNC-Machining Rapid Prototyping

  20. Electrical Connection Scheme

  21. Vertical Collaring (Hardly Possible for 10-m-long Magnets)

  22. Horizontal Collaring Self-locking collars Collaring Press Assembly mandrel

  23. Large Magnet Facility (Building 180) Cable insulation Ex-Ansaldo winding machine Alignment tables Welding press area Ex-Jeumont winding machine

  24. Re-Commissioning of Tooling in 927 Winding machine Curing press Design and Construction of the MQXC J.C. Perez TE/MSC-ML 22 July 2009 24 Modulus tester

  25. Corrector Package MCXSO MCXO MCXSSMCXS MCXT MQXS MCXBV MCXH IP ~0.5 m ~0.5 m ~0.5 m ~0.9 m ~1 m ~1 m

  26. MCXB 4-Block Design 1000 Ø570 Ø140 Field strength 1.5 Tm Operating temp 1.9 K Current 2.4 kA Inductance 10 mH New 4.37 mm cable & Polyimide insulation Self-supporting collars Single piece yoke

  27. Milestones… (MCXB & MQXS) Parameter list October 09 / January 10 Magnetic and mechanical design November 09 Fabrication drawings May 10 Trial coils July 10 Mechanical model May 10 / July 10 Model magnets completed December 10 Technical specifications March 11 Industrial contracts July 11 Pre-series magnets July 12 Series production September 12 / December 13

  28. Correctors in Q2 Q3 Q2b Q2a Q1 MQXC MCXBV (MCXBHV?) MCXBH (MCXBHV?) MQXC MQXC MQXC 10 m 1..1.3 m 7 m 7 m 1..1.3 m 10 m • To reach the same level as the effective BPM resolution: • Provide 1.5 Tm (1.8 Tm) in H&V-plane in BOTH locations. • Feasibility study underway on combined H/V-corrector that meets the reliability requirements (Report by Mid-2010 + Model work..) • An extra H/V pair means: • Magnet R&D, material R&D, design, component & tooling procurement • Additional powering and protections circuits

  29. Planning (Only MQXC) Instrumented collar test Component procurement Tooling procurement Coil winding Cold testing 2-m-long model

  30. Collaboration Website

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