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Long-Baseline Neutrino FacilityLBNF
LBNF Horns Update
Cory Crowley
BIWG
December 05, 2019
LBNF
Outline
12.05.19 Cory Crowley | LBNF Horns Update2
• Horn A Design Status
• Horn Design Considerations for B & C
• Module Design Status
• Upcoming Work
LBNF
Horn Design – Horn A FEA
3
• Inner & Outer Conductors Analyzed Last Year
– Acceptable max temperatures of 65C & min S.F. of 2.2
w/6061-T6. Increase to 2.8 w/6013-T6 due to fatigue life
increase (124MPa vs. 97MPa).
– Should take advantage of better materials on inner
conductor & high-stress stripline regions.
• Stripline
– Analyzed for temperature & stress concerns, basic modal
analysis. Must be experimentally tested & verified.
FEA Credit: Zhijing Tang / Ang Lee
12.05.19 Cory Crowley | LBNF Horns Update
LBNF
Revision in Progress
4 12.05.19 Cory Crowley | LBNF Horns Update
Make this 400mm?
• Requested change per RAL integration meeting 12/4/19.
• John Back is currently analyzing & this will likely be a reality by next
week.
LBNF
Still Gauging Impact of Updates
5
• Most significant update is different target design.
– Shorter target length (~150cm) & no D.S. target mount needed.
– Cone transition on U.S. end (which horn A must mimic) to reduce deflection.
• Should reduce horn EDEP further on D.S. end where most problematic.
• Stress / erosion concerns arose after NuMI Horn prototype disassembly.
– Found that wear resistant nickel coating wore through in several areas.
• Horn A inner conductor changed from 2mm thick to 2.5mm thick to allow
more material for stress distribution / reduced joule heating / Safety
Factor.
• Endcap had to be stiffened throughout analysis iterations due to high
magnetic stresses from 300kA pulse.
• Thicker wall also helps keep circularity requirements due to 30cm
diameter cone on U.S. end & keep conservative design with unknown
erosion effects, 300kA pulse, variability in cooling, etc…
• Still need to document heat input into horn A I.C. from hot target tube.
12.05.19 Cory Crowley | LBNF Horns Update
LBNF
Horn Design – Current Design Status (Horn A)
6 12.05.19 Cory Crowley | LBNF Horns Update
LBNF
Horn Design – Current Design Status (Horn A)
7 12.05.19 Cory Crowley | LBNF Horns Update
LBNF
Horn A Design Prototypes – Water Ports
8
• LBNF Horns pursue a revision of port design as
compared to NuMI / BNB. Different from T2K as well.
• Small footprint, inexpensive, immediate assembly,
higher pressure rating, & reduced component count.
• Required prototype testing in preparation for design
review & to verify resilience of concept.
12.05.19 Cory Crowley | LBNF Horns Update
LBNF
Horn A Design Prototype – Conductor Supports
9
• Conductor supported by 3 rods in tension as opposed to compression.
• Tension method required for larger horns due to L^2 term in critical
buckling denominator. ~1.5m diameter horns would need large
spacers if using available designs.
• Desire to make a resilient, minimal mass, universal conductor support.
12.05.19 Cory Crowley | LBNF Horns Update
LBNF
Horn A Design Prototype – Conductor Supports
10
• Prototype / Design Advancement
– Full thermal, stress / cyclic fatigue, & water flow analysis.
– Built mockup for technician assembly training / design
review aid.
– Electrical analysis remains for ~800V.
Print Credit:Quinn P.
FEA Credit: Ang Lee& Jacob Kintner
12.05.19 Cory Crowley | LBNF Horns Update
LBNF
Horn Design – Considerations for Horns B & C
11
Max V@PS
Max Allow. E Field
Max Isolator PathLength Potential
Horn AΔV
Horn BΔV
Horn CΔV
~3700V 35V/.001” 5V/.001” ~550V ~1550V ~1050V
EE Credit: Ken Quinn
12.05.19 Cory Crowley | LBNF Horns Update
LBNF
Horn Design – Horns B & C FEA
12
• Inner & Outer Conductors
– Very resilient designs utilizing 6061-T6. Max conductor temp 28C, need to
incorporate equalization sections (80C) into actively cooled conductor volume.
• Stripline
– Analyzed temperature &
stress, basic modal analysis.
Must also be experimentally
tested & verified. B & C
design should be a mirror.
FEA Credit: Zhijing Tang / Ang Lee
12.05.19 Cory Crowley | LBNF Horns Update
LBNF
Design Plan
13 12.05.19 Cory Crowley | LBNF Horns Update
• Would like to confirm:
– Outer conductor diameter is large enough that incorporation of
equalization sections has no impact.
– Flaring of I.C. to reach O.C. outside of advertised focal length has trivial
impact on physics.
• Good models will take a little time, but I could provide dimensions for
flux simulations that would be on par with what Laura used for
optimization effort. Is this of use? Or better to wait?
LBNF
Module Design – Horn Integration
14
• Mainframe Placement
– Endwalls & stripline shielding
block (SLB).
• Challenging SLB Connection
– Increased clamping surface area.
– Increased voltage potential at
Horn C (3.7kV).
– Increased reusability / resilience.
12.05.19 Cory Crowley | LBNF Horns Update
LBNF
Module Design – Horn & Target Integration
15
• Challenges
– SLB Connection
– Utility feedthroughs
– Voltage Issues
– More and more and more…..
12.05.19 Cory Crowley | LBNF Horns Update
LBNF
Module Design – Mainframe & Motion Control
16
• Construction
– Plate frame, pinned & bolted.
– Select areas of stainless steel where required.
– Allows for ¾” gap to all shield blocks for remote
alignment of horn.
– Designed for life of facility.
• Motion Control Concept
– Simple sliding block & pad joints for horizontal
translation.
– Vertical actuation internal to module mainframe.
Design Credit: Mike Campbell
12.05.19 Cory Crowley | LBNF Horns Update
LBNF
Major Push: Standardization of Ancillary Structures
17
• Everything needs to have identical distance to beam centerline.
– Stripline block pads.
– Carriage Support Beams.
– Stripline Connection Point to Horns.
12.05.19 Cory Crowley | LBNF Horns Update
LBNF
Working Towards Improving Cartoons
18
• Engineering placeholders need to be improved.
– Conductor Profiles
– Stripline Design
– Water tanks
– Connections to Modules
12.05.19 Cory Crowley | LBNF Horns Update
Design Credit: Mike Campbell
LBNF
Summary
19
• Horn & Support Structure design progressing according to plan.
• Roughly 1 year remaining on final design of Horn A, followed by
fabrication start of conductors & stripline components.
• Anticipating additional prototyping:
- Critical stripline ceramics (~1000+).
- Horn A + Stripline.
- Horn B & C Stripline.
• Need to advance Horn B & C conductor design to help advance
target chase / modules / simulations...
• Likely going to re-analyze Horn A stripline due to design
changes, but Horn A conductor analysis still valid after transition
to cone on U.S. end. Should be judicious with FEA (Time / $$$).
• What should I provide? Horn B & C revised equalization specs?
12.05.19 Cory Crowley | LBNF Horns Update