CM 26 Riverside...Window fabrication Metal at the thinnest part only 180 micron thick Window machined with a 27” swing ROMI CNC lathe & CNC Fadal 50” x 20” 5020A Vertical Machining

CM 26 – Riverside

24th – 27th March 2010

Engineering Summary

Presented by Wing Lau

RF Power by Andy Moss

EMR Installation by Alain Blondel

Window fabrication by Don Summers

Diffuser by John Cobb

Solid Absorber clamping arrangement by Wing Lau

Radiation Shield by Andy Nichols

Discussion on the TOF Shield support bracket

production problems

Contributions

The system as it

is at DL currently

RF Power status

•Connected to its test

load, tested water

flows - no leaks !

•Manufactured input

sliding short for input

tuning

•tested operation of

grid and anode tap

moving circuits

The done list on the TH116 Amplifier



load, tested water

flows - no leaks !



tuning


grid and anode tap

moving circuits

Test TH116 triode in

amplifier HT tank

Water connections

HT connection

visible, water feed

and return are inside

this connectionPTFE insulation

116 HT Tank


This part of the amplifier is up at 40kV,

arcing will damage silver plated

components – takes months to fix!


load, tested water

flows - no leaks !



tuning


grid and anode tap

moving circuits

Test TH116 triode in

amplifier HT tank

Water connections

HT connection

visible, water feed

and return are inside

this connectionPTFE insulation

116 HT Tank


This part of the amplifier is up at 40kV,

arcing will damage silver plated

components – takes months to fix!

Installed arc detector, smoke alarm

and camera to monitor conditions

inside the HT tank remotely

Will run up the amplifier gently so as

to understand how to operate it.


load, tested water

flows - no leaks !



tuning


grid and anode tap

moving circuits

HT Power supply -The done list

•PLC controller tested

•Filament heater tested to full power on the test triode

•Cathode bias unit tested to operation levels

•System earthing assessed and corrected to promote

return current path back through monitor circuits







Still to do list

Some wiring between amp and HV rack / Aux rack

Built & Test Cathode modulator

Test Crowbar circuit

HV pressure test of amplifier & HV components







Still to do list

Some wiring between amp and HV rack / Aux rack

Built & Test Cathode modulator

Test Crowbar circuit

HV pressure test of amplifier & HV components

• Altronic Reaserch water

load, already tested to

3MW pulse

• Load (smaller!)

• Water cooling plant

• Much smaller than our

current test load - a

positive design change

for the hall installation

• Possibility to have one

cooling plant for

multiple waveguide

loads -ideal for MICE

due to low average

power

RF Load

Model 43200

(back view)

• Altronic Reaserch water

load, already tested to

3MW pulse

• Load (smaller!)

• Water cooling plant

• Much smaller than our

current test load - a

positive design change

for the hall installation

• Possibility to have one

cooling plant for

multiple waveguide

loads -ideal for MICE

due to low average

power

RF Load

Model 43200

(back view)

Hall implementation

Will use 3D CAD

drawings to understand

how to fit RF equipment

under the floor system

build up;

Need to look for phase

shifter and hybrid

devices to reduce the

size

N2 pressure will be

used for whole

waveguide system to

raise voltage stand off

and provide a “W/guide

complete” interlock.

Amplifier to cavity installation 1 – using

amplifier with DL/LBNL typical layout

RF Loads

Amplifier to cavity installation 1 – using

amplifier with CERN typical layout

RF Load

Summary on RF work

• Large amplifier ready for testing, connected to water,

test load and checked with network analyser as far as

possible

• Some work remains on the power supply, this will

continue as staff effort allows

• Hall design in progress and components being

identified that will be better for the installation, need to

progress to 3D CAD models as soon as possible

• Committed RF effort for this year to fully test amplifier

system

Module M0 prototype under testing

First test module (2 crossed planes,

2 x 0.8mm dia. Fibre / bar)

EMR production status



2 0.8mm dia. Fibre / bar)

New modules now in production

Guide for fibre insertion and

gluing (20 bar in a row)


Go

ing to

te

st

roo

m s

oo

nR

ea

dy fo

r p

lan

e a

sse

mb

ly

1 stand for plane assembly1 stand for Module

assembly & storage





Module assembly awaiting PMT

connector gluing & electronic

integration - 1st one with 1mm dia

fibre will be tested soon with

cosmic!








integration - 1st one with 1mm dia

fibre will be tested soon with

cosmic!

Design work on the parts close

to PMT (PMT, FEB electronics,

shielding block etc) is being

finalised








integration.

1st one with 1mm dia fibre will be

tested soon with cosmic!

Design work on the parts close

to PMT (PMT, FEB electronics,

shielding block etc) is being

finalised

Here is the whole EMR assembly –

but the shielding is an issue!

Shielding tubes


There was an issue with magnetic

stray field ….. Up to 1200 Gauss

No individual shielding tube could

withstand this.

EMR simulation study




withstand this.

Then, the blondel’s plate came along

and halts back the stray field invasion





withstand this.



Further iteration gives this


Mumetal




withstand this.



Further iteration gives this….

….and this


Virostek & Blondel plate at PMT2

Due to s

atu

ratio

n w

ith M

um

eta

l

(Arm

co g

ives b

etter

results)




withstand this.



Baseline for EMR shielding now:-

-1 global plate (50mm thk in Armco or

equivalent);

- Individual tube for each PMT (1mm

thk in Armco)


There was also an FEA study on the mechanical behaviour of the

assembly due to transportation, gravity and handling loads – Blondel

plate not included so far


Requires a clear envelop of

1.9x1.9x1m

Need to check if this fouls with

hall building structures etc

EMR integration at MICE Hall

Requires a clear envelop of

1.9x1.9x1m

Need to check if this fouls with

hall building structures etc

EMR outer box must comply

with the different STEPS

(moving downstream) to ensure

no interference with platform.

EMR integration at MICE Hall

Question from the floor

A question was raised by Mike Courthold:

Would the newly added EMR shielding plate, which is 50mm thick, undermine the effectivity of the existing magnetic shielding wall in constraining the stray magnetic field at the boundaries of the MICE Hall to less than 5 gauss, according to regulations imposed on us by RAL Safety group?

Question from the floor

A question was raised by Mike Courthold:

Would the newly added EMR shielding plate, which is 50mm thick, undermine the effectivity of the existing magnetic shielding wall in constraining the stray magnetic field at the boundaries of the MICE Hall to less than 5 gauss, according to regulations imposed on us by RAL Safety group?

It was agreed that Frank Cadoux and Mike Courthold should check this. Or, Frank could check by how much the magnetic shielding wall modifies the magnetic field in the vicinity of the EMR shield.

Window fabrication

Metal at the thinnest part only 180 micron thick

Window machined with a 27” swing ROMI CNC

lathe & CNC Fadal 50” x 20” 5020A Vertical

Machining Centre

Window fabrication




Machining Centre

Total of 20 windows – 6 LH2 & 6 Safety Windows;

5 spares & 3 for burst test

Window fabrication




Machining Centre



11 Windows done & 2 burst tested at room temp. (

burst at 120 & 122psi – FEA shows 115 psi)

Window fabrication




Machining Centre





QA – Mississippi own measurement using deep

throat micronmeter + non-contact CMM at LBL

Window fabrication




Machining Centre







Burst test at 77K still to be done. Preparation is

now underway

Window fabrication




Machining Centre








now underway

Shipping hats will have transparent top & bottom

cover plate to enable non-invasive custom

inspection

Window fabrication




Machining Centre








now underway

Shipping hats will have plastic top & bottom cover

plate to enable non-invasive custom inspection

2 further ultra thin windows (estimated to be about

70 microns thin) using Lithium-Al. alloy still to be

made and burst tested, at 77K &300K for future

design (not MICE)

The 3-step operation:

Carousel – moves disc to position

“30 degree” – transfer disc from carousel to carrier

Carrier – moves disc in/out of solenoid

There are 160 pins & holes to align

a tricky operation!

Diffuser






a tricky operation!

Progress:

Cool catches made – for ease insert / hard extraction

Mock-up of Disc-holder – Carrier

-- test various ideas for locking pins

-- develop transfer procedure

Diffuser

Invaluable to gain

understanding of

how it works






a tricky operation!

Progress:

Cool catches made – for ease insert / hard extraction

Mock-up of Disc-holder – Carrier

-- test various ideas for locking pins

-- develop transfer procedure

Learnt a lot from this

Floating carrier developed –

40 springs allow L/R, U/D & BF compliance of 0.5-

1mm

Most components now made!

Diffuser

Controls

Fibre optic link – hardware done; prototype still to be developed;

FPGA firmware -- Basic manual control done; remote control to be developed

Labview control – still to be developed

Encoder (must align relative rotation to within 3 microns) – 2 out of 3 tested

Overruns – reproducible to 0.25mm, expected to be only a fraction of mm

Controls

Fibre optic link – hardware done; prototype still to be developed;

FPGA firmware -- Basic manual control done; remote control to be developed

Labview control – still to be developed

Encoder (must align relative rotation to within 3 microns) – 2 out of 3 tested

Overruns – reproducible to 0.25mm, expected to be only a fraction of mm

Still to do

Hardware – Dis-/ re-assemble with new components;

Install alignment rings for disc holder in zero-position;

Guards, installation drawings etc

Firmware – Develop FPGA firmware & RS232 interface

Controls – Develop Labview control

Develop EPICS when Firmware system is developed

Acceptance test – Number of unaided disc transfer & Acceptance criteria

to be agreed;

Have allowed 6 weeks in our schedule

Diffuser

Schedule

Mechanical

Control Hardware &

Firmware

Mechanical & Control

integration

Acceptance tests

Installation drawings

Installation

Quench test

Install in tracker

Integration with EPICS

Ma

rch

Ap

ril

Ma

y

Ju

ne

Ju

ly

Au

g

Se

pt

Oct

Nov

Dec

Ja

n

Feb

Ma

rch

2010 2011

Ap

ril

Solid Absorber clamping arrangement

70

mm

> 500mm

Entrance clearance to the

spool piece: ~ 500 x 70mm

Space constraint

Warm

bo

re

cle

ar

dia

me

ter:

47

0 +

/-2

mm

AFC Warm bore


70

mm

> 500mm

Entrance clearance to the

spool piece: ~ 500 x 70mm

Space constraint

Warm

bo

re

cle

ar

dia

me

ter:

47

0 +

/-2

mm

AFC Warm bore

Overall dimension of clamp with

absorber must be under 468 x 70mm


Space constraint

Three

brackets to

lock tight

the clamp

ring to the

absorber


Space constraint

Three

brackets to

lock tight

the clamp

ring to the

absorber

Dimension check

Mounting it to the AFC

Adaptor connecting the solid

absorber to the Safety Window

mounting flange





mounting flange

Bolted onto the

underside of the spool

piece cover plate





mounting flange

Bolted onto the

underside of the spool

piece cover plateThings to do:

• To decide

whether the

clamp band is to

be made of

carbon fibre or

stainless steel –

Alan Bross to

decide and

advise

• To produce

fabrication

drawings –

Oxford to provide

• Fabrication by

Fermilab


Radiation Shield inside the Spectronmeter

Radiation shutter assembly

Is bolted to spectrometer

solenoid #1 prior to Step IV

Two guided lead shutters

Remotely operated, but with

Manual control in reserve

Control rods have to

penetrate MICE vacuum

volume

Design work is nearly

complete

• Shutter doors and guides have been made at

FNAL, awaiting/undergoing fit check before

shipping

• All detail design work is done by Peter Lau

• Some potential manufacturing difficulties need

sorting out, nothing major

• Probably some scope for simplifying the control

rods and actuation

Progress Status

Radiation Shield inside the Spectrometer

• Completion of manufacturing drawings:

– End of April, 2010

• Shipment of shutters & guides to RAL

– Q2/3, 2010?

• Design and manufacture of pre-assembly test stand

– Mid-May, 2010

• Trial assembly and testing prior to installation

– Q4, 2010

• Final installation in MICE

– Difficult to tell just now – linked to Step IV

Remaining work and schedule plans

Discussion session

There were concerns raised on the Iron Shield Support brackets:-

1. The workmanship on the welds is not good. He is concerned at

the weld size on the bracket joints.

2. There was no specification on what the weld size should be,

resulting in fabricators welding the bracket with nominal weld

throat

3. At some of the joints, the fillet weld meant that the Iron Shield

which was machined with no fillet or chamfer can not fit into the

bolt holds...

4. It was not sure what external load the brackets were assessed

to and what the safety margins are on these brackets;

5. No Assembly drawing was available to show where the parts

go....

6. We need to decide if these brackets need to be re-made or re-

welded.....

1. There is a stress report on these brackets.

Apart from the gravity load that hangs on the top and bottom

brackets, there is a total of 8 tons of horizontal loads (magnetic

load)shared between the 4 brackets.

The stress from the FE analysis showed that the stresses on

these brackets are generally very low (about 35 - 40 MPa,

compared to an allowable of 235 MPa), except two areas where

the local stress is about 85 MPa.

2. Design was done based on a full joint efficiency, meaning that the

joints are of fully penetrated welds. Apart from the two brackets

which have slightly higher stresses, a fillet weld of 10mm should be

OK.

Wing Lau agreed to take the FE results and extrapolate them to

see what stress should be if the joints for a 10mm fillet weld.

A meeting was convened afterwards to discuss the issues

3. The drawings made by Oxford were "Design Drawings". Design

drawings only show basic dimensions. They do not list out the details

such as tolerance and weld sizes etc. Such information are normally

shown in "Production Drawings".

4. Production drawings were not done in this case and instead the

design drawings were sent out to manufacturers for fabrication.

5. Of the two brackets need to be re-welded / re-made.

6. The drawings specified that the bracket material to be Stainless

Steel. Yamour to check if they are indeed made of SS, and not

carbon steel.

A meeting was convened afterwards to discuss the issues

Documents

CM 26 Riverside...Window fabrication Metal at the thinnest part only 180 micron thick Window machined with a 27” swing ROMI CNC lathe & CNC Fadal 50” x 20” 5020A Vertical Machining