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Coil End Design, Winding Test and End Parts Fabrication. Susana Izquierdo Bermudez 2 nd Joint HiLumi LHC/LARP Annual Meeting 15/11/2011. Coil Ends Design Strategy. Exchange the set of designed spacers. Common parameters. z 4. z 3. z 2. d min. z 1. L total. Cable dimension - PowerPoint PPT Presentation
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Coil End Design, Winding Test and End Parts
Fabrication
Susana Izquierdo Bermudez2nd Joint HiLumi LHC/LARP Annual Meeting
15/11/2011
Coil Ends Design Strategy
CERN
Define a set of common parameters
Design of coil ends using ROXIE
Tests
Converge to an unique geometry
Production of a unique set of end spacers
LARP
Design of coils ends using
BEND
TestsExchange the set of designed 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
• Geometry of the layer jump
Ltotal
z3z4
z2z1
dmin
3
Coil Ends Design @ CERN1st approach (as HQ): z-position of the blocks optimized to min. peak field and opt. harmonics
2nd approach: Redistribute the conductors in three blocks per layer (not much more than 10 turns per block)
Based on CERN XsecROXIE
Block 1Block 2
Block 3Block 4
Block 1Block 2.aBlock 2.b
Block 3Block 4.aBlock 4.b
0.00 50.00 100.00 150.00 200.007.00
8.00
9.00
10.00
11.00
12.00
13.00
14.00
15.00
Block 1 Block 2.a Block 2.bBlock 3 Block 4.a Block 4.b
Arc length of the first strand in the block (mm)
Peak
fiel
d in
the
bloc
k (T
)
0.00 50.00 100.00 150.00 200.007.00
8.00
9.00
10.00
11.00
12.00
13.00
14.00
15.00
Block 1 Block 2 Block 3 Block 4
Arc length of first strand in the block (mm)
Peak
fiel
d in
the
bloc
k (T
)
4
Reproduction of a geometry defined by BEND in ROXIE
For a given A-length and winding angle, very close geometries can be found for the “male” surface of the spacer.
0 5 10 15 20 25 300
5
10
15
20
z [mm]
x [m
m]
0 5 10 15 20 25 3070
75
80
85
90
95
z [mm]
y [m
m]
BEND IDBEND ODROXIE ID DIF. GEO. H=2.6ROXIE OD DIF. GEO. H=2.6
0.3 mm
A-length
𝛽
5
Winding Test
AIM: Determine the mechanical stability of the cable
• Based on MQXF3_v0 Cross-Section.• Return End + Lead End pole pieces, inner layer.• 3D 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
Insulation: Plasma coating + layer of fibre glass.
11T, J. Mazet
Parts Manufacturing method Manufacturing time
Winding tests & First Copper coil Plastic rapid prototyping < 3 weeks
Practice coils & First coils with Stainless Steel Laser Sintering 3 weeks
Final parts Machining 3 months
7
Additional slides
0 5 10 15 20 25 3070
75
80
85
90
95
z [mm]
y [m
m]
BEND IDBEND ODROXIE ID CONSTANT PERIMROXIE OD CONSTANT PERIM
0 5 10 15 20 25 3070
75
80
85
90
95
z [mm]
y [m
m]
BEND IDBEND ODROXIE ID DIF. GEO. H=2ROXIE OD DIF. GEO. H=2ROXIE ID DIF. GEO. H=2.4ROXIE OD DIF. GEO. H=2.4ROXIE ID DIF. GEO. H=2.8ROXIE OD DIF. GEO. H=2.8
0 5 10 15 20 25 300
5
10
15
20
z [mm]
x [m
m]
0 5 10 15 20 25 300
5
10
15
20
z [mm]
x [m
m]
Differential Geometry Ends vs. Bend
Constant perimeter vs. Bend
10
