Meeting_060426_LARP_LRSS

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					Long racetrack supporting structure

     Paolo Ferracin and Dan Cheng


         LARP Collaboration Meeting
                   LBNL
            April 26 - 28, 2006
                              Outline
• Introduction

• Magnet design

• Assembly and pre-loading

• Magnetic analysis

• Mechanical analysis

• Test plan

• Current status and next steps

04/26/2006                              Paolo Ferracin
                             Introduction
• Task goals
   • Provide supporting structure for test of 4 m long racetrack coils
   • Develop a shell-based supporting structure for long magnets

• Steps
   • Design, procure the structure
   • Define a procedure for assembly and disassembly
   • Test structure at LBNL with dummy coils
   • Check uniform load with
        • Strain gauges mounted on the shell
        • Pressure sensitive films
     • Ship structure to BNL

• Design based on the support structure for the SM program


04/26/2006                                                  Paolo Ferracin
                              Outline
• Introduction

•   Magnet design

• Assembly and pre-loading

• Magnetic analysis

• Mechanical analysis

• Test plan

• Current status and next steps

04/26/2006                              Paolo Ferracin
                              LR cross-section
• With respect to SM design

     • Aluminum shell
        • Larger diameter: 305 mm

     • Thicker iron yokes
         • Bigger yoke gaps

     • Simplified iron pads

     • Thicker stainless steel skins

     • 2 bladders and 4 loading keys
       for assembly and pre-load
         • 2 pull shims for bladder
           removal


04/26/2006                                       Paolo Ferracin
                                 LR 3D design
•   Aluminum shell
     • Single piece
     • Length: 3.6 m

•   Iron yokes
     • 50 mm thick laminations

•   Iron pads
     • Half length (1.8 m)

•   Stainless steel skins
     • Full length (3.6 m)

•   Bladders
     • Half length (1.8 m)

•   Keys and shims
     • Half length (1.8 m)


04/26/2006                                      Paolo Ferracin
                               Outline
• Introduction

• Magnet design

•   Assembly and pre-loading

• Magnetic analysis

• Mechanical analysis

• Test plan

• Current status and next steps

04/26/2006                               Paolo Ferracin
             Assembly-related components
• Handling rafts can be configured for installation
  operations as well
• Installation beam




04/26/2006                                       Paolo Ferracin
                      Assembly Process
• Raft and bottom cradles placed
  onto ~25’ of granite/surface table
• Aluminum shell is placed into
  cradles


• Upper raft is configured into
  installation fixture




04/26/2006                               Paolo Ferracin
                        Assembly Process
• Cantilever portion of installation raft is
  then inserted into the empty aluminum
  shell
• Yoke half lamination is assembled on
  non-inserted portion of the installation
  beam
• Yoke half is inserted into the shell




04/26/2006                                     Paolo Ferracin
                        Assembly Process
• Raft is disconnected and reconfigured
• Pull shims inserted
• Compact cylinders are pressurized to 300 psi
   • Applies small load keep yoke from shifting
     during rotation operation
• Rotate assembly
   • Two-crane (or main/aux. hook) operation
   • Or rotation wheels
• Remove top raft
• Bleed pressure




04/26/2006                                        Paolo Ferracin
                       Assembly Process
• Reconnect installation beams to handling raft
• Pull assembly beam from shell internals
• Remove internal cradle supports
• Reinsert installation beam
• Rinse, lather, repeat:
   (Assemble 2nd yoke half, insert)




04/26/2006                                        Paolo Ferracin
                      Assembly Process
• Pressurize cylinder manifold to 300 psi
• Insert gap keys (and necessary shims)
• Bleed cylinder pressure
• Remove installation beam from center
• Yoke halves are now only resting on gap keys




04/26/2006                                       Paolo Ferracin
                      Assembly Process


• Reconfigure installation raft
   • Replace beam standoffs
   • Remove cantilever installation beam




04/26/2006                                 Paolo Ferracin
                      Assembly Process


• Align installation beam slots to yoke key slots
• Insert coil pack onto beam w/keys




04/26/2006                                          Paolo Ferracin
                      Assembly Process
• Insert pull shims with
  bladders
• Load yokes with bladder
  pressure
• Insert necessary shims
• Remove gap keys, etc.
  from between yokes
• Bleed HP




04/26/2006                               Paolo Ferracin
                              Outline
• Introduction

• Magnet design

• Assembly and pre-loading

•   Magnetic analysis

• Mechanical analysis

• Test plan

• Current status and next steps

04/26/2006                              Paolo Ferracin
                     2D magnetic analysis
                    Flux lines and peak field
• “Common-coil” (quadrupole) flux line profile
• Peak field located in the inner surface of the coil, approximately
  between turn 11 and turn 13.




04/26/2006                                                Paolo Ferracin
                      2D magnetic analysis
                       Magnet parameters

• Jc (4.2 K, 12 T) = 2800 A/mm2

• Cu/SC = 0.9


• Bpeak (4.2 K) = 12.2 T


• Iss (4.2 K) = 10.8 kA


• Stored energy (4.2 K) = 86 kJ/m


• Inductance (4.2 K) = 1.5 mH/m

04/26/2006                                   Paolo Ferracin
                      3D magnetic analysis
                        Field in the ends
• The field decreases from 12.2 T
  at the center to 11.6 T at the
  end of the straight section
• In the end region, the field
  further decreases to 11.0 T




04/26/2006                                   Paolo Ferracin
                              Outline
• Introduction

• Magnet design

• Assembly and pre-loading

• Magnetic analysis

•   Mechanical analysis

• Test plan

• Current status and next steps

04/26/2006                              Paolo Ferracin
                     2D mechanical analysis
                         Lorentz forces


• At short sample current

     • Fx (quadrant) = + 1903 kN/m

     • x = 62 MPa


     • Fy (quadrant) = - 9 kN/m

     • y < 1 MPa



04/26/2006                                    Paolo Ferracin
                     2D mechanical analysis
                      Coil horizontal stress
• After cool-down                   • At full field

     About 30 MPa coil pre-stress       75 MPa of coil max. stress




04/26/2006                                                Paolo Ferracin
                      2D mechanical analysis
                        Tolerance analysis

• Tolerance of the components
   • Shell ID
        -0.000” / +0.0025”
     • Yoke OD
        -0.003” / +0.000”
     • Yoke key slot
        - 0.002”/ +0.002”
     • Pad thickness
        • -0.003” / +0.003


• Total range
   • -0.008” / +0.008


04/26/2006                                     Paolo Ferracin
                        3D mechanical analysis
                          Mechanical model

• 3D geometry

     • Full length
         • Interaction between shell
           and yoke in the axial
           direction

     • Straight section of 300 mm
         • Effect of axial Lorentz
           forces on the contact area
           coil-island




04/26/2006                                       Paolo Ferracin
                         3D mechanical analysis
                       Contraction of aluminum shell
• 4 m long shell                                      Friction = 0.0

• Shell azimuthal stress at 4.3 K
     •  = 150 MPa


• Frictionless model
     • Shell z contraction = 9.5 mm
         • (αshell lshell) + ( / Eshell  lshell)
     • Yoke z contraction = 3.9 mm                    Friction = 0.2
         • (α yoke lyoke)
     • Relative z shell-yoke = 5.6 mm
• Friction model (µ = 0.2)
     • Shell z contraction = 5.7 mm
     • Yoke z contraction = 4.2 mm
     • Relative z shell-yoke = 1.5 mm


04/26/2006                                                             Paolo Ferracin
                       3D mechanical analysis
                       Coil-island contact region
• Frictionless model
   • After cool-down
        • Coil: z = + 20 MPa
        • Island: z = - 50 MPa
        • Fz contact = ~ 20 kN
     • Still contact at high field




04/26/2006                                          Paolo Ferracin
                       3D mechanical analysis
                       Coil-island contact region
• Friction model
   • After cool-down
        • Fz contact = ~ 10 kN
     • Friction is limiting axial
       motion
     • Still contact at high field




04/26/2006                                          Paolo Ferracin
                              Outline
• Introduction

• Magnet design

• Assembly and pre-loading

• Magnetic analysis

• Mechanical analysis

•   Test plan

• Current status and next steps

04/26/2006                              Paolo Ferracin
                              Test plan
• Insertion of pressure sensitive
  films
    • Dummy coils – skins
    • Load keys – yoke/pads
• Strain gauges
    • Mid-plane (both sides)
    • 5 axial locations
    • Y and Z directions
    • Temperature compensators
    • Total: 40 gauges
• Test plan
    • Pressurize bladders and
      insert keys in several steps
    • Monitor stress level and
      uniformity
    • Inspect pressure sens. films

04/26/2006                                Paolo Ferracin
                               Outline
• Introduction

• Magnet design

• Assembly and pre-loading

• Magnetic analysis

• Mechanical analysis

• Test plan

•   Current status and next steps

04/26/2006                               Paolo Ferracin
                         Current status (I)
• Engineering design of all the components completed
• Magnetic analysis
   • Computation of peak field, load line, and field in the ends
• Mechanical analysis
   • Stress in the coil after cool-down and at high field
   • Effect of fabrication tolerances
   • Sliding between shell and yoke
   • Contact coil-island during excitation
• Assembly procedure defined
• Procurement
   • Aluminum shell, tie rods, dummy coils available
   • Yoke and pads by the end of May



04/26/2006                                                  Paolo Ferracin
             Current status (II)




04/26/2006                         Paolo Ferracin
                           Next steps

• May
   • Finalize handling structure design & detail drawings
        • Handling rafts (detail drawings in progress)
        • Cradles (detail drawings in progress)
        • Winch mounts & pulling structure (to be designed)
     • Instrument shell with strain gauges

• June - July
   • Magnet assembly
   • Load test

04/26/2006                                          Paolo Ferracin

				
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