MQXF support structure An extension of LARP experience Helene Felice MQXF Design Review December 10...
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Transcript of MQXF support structure An extension of LARP experience Helene Felice MQXF Design Review December 10...
MQXF support structureAn extension of LARP experience
Helene Felice
MQXF Design Review December 10th to 12th , 2014
CERN
LQLongQuadrupoleLQS01a-b/02/03
LRLong RacetrackLRS01-02
HQHigh-field QuadrupoleHQ01a-b-c-d-eHQ02a-b / HQ03a
Snapshot of LARP support structure experience
12/10/2014Helene Felice 2
Length
Time
2004
2014
2005
2006
2007
2008
2009
2010
2011
2012
2013
0.3 m 1 m 3.6-3.7 m
SQSubscale quad
TQTechnology QuadrupoleTQS01/02a-b-c/03a-b-c-d
LRLong RacetrackLRS01-02Length demonstration
LQLongQuadrupoleLQS01a-b/02/03Some accelerator quality featuresLength with cos2qAccommodating variability in coil dimension
HQHigh-field QuadrupoleHQ01a-b-c-d-eHQ02a-b / HQ03aAccelerator quality featuresMechanical alignment
Step-by-step technology demonstration
12/10/2014Helene Felice 3
Length
Time
2004
2014
2005
2006
2007
2008
2009
2010
2011
2012
2013
0.3 m 1 m 3.6-3.7 m
SQSubscale quadConcept
TQTechnology QuadrupoleTQS01/02a-b-c/03a-b-c-dConcept on cos2qTechnology selection Scale-up & design optimization
LRLong RacetrackLRS01-02Length demonstration
LQLongQuadrupoleLQS01a-b/02/03Some accelerator quality featuresLength with cos2qAccommodating variability in coil dimension
HQHigh-field QuadrupoleHQ01a-b-c-d-eHQ02a-b / HQ03aAccelerator quality featuresMechanical alignmentHigh stress regime
Exploration of the stress limits
12/10/2014Helene Felice 4
Length
Time
2004
2014
2005
2006
2007
2008
2009
2010
2011
2012
2013
0.3 m 1 m 3.6-3.7 m
SQSubscale quadConcept
TQTechnology QuadrupoleTQS01/02a-b-c/03a-b-c-dConcept on cos2qTechnology selectionUltimate stress exploration
Scale-up & design optimization
Outline
• Shell-based support structure concept• Exploring the limits
– TQ high stress • Step-by-step technology demonstration
– Design optimization– Length
• QXF support structure– Main features
12/10/2014Helene Felice 5
Helene Felice 6
Shell-based support structureMotivation and concept
12/10/2014
• Shell-based support structure often referred as “bladder and keys” structuredeveloped at LBNL for strain sensitive material
coil
pad
shell
Shell-based support structure Supporting tools
12/10/2014Helene Felice 7
• Numerical tools
• Instrumentation
• Assembly based on analysis• Control of the pre-stress level• Constant feedback between
SG measurements and model
Helene Felice 8
Shell-based support structureConcept
12/10/2014
• Shell-based support structure often referred as “bladder and keys” structuredeveloped at LBNL for strain sensitive material
Helene Felice 9
Shell-based support structureConcept
12/10/2014
Displacement scaling 30
• Shell-based support structure often referred as “bladder and keys” structuredeveloped at LBNL for strain sensitive material
Inflated Bladders
Bladder
Helene Felice 10
Shell-based support structureConcept
12/10/2014
• Shell-based support structure often referred as “bladder and keys” structuredeveloped at LBNL for strain sensitive material
Displacement scaling 30
Shimming of the load leys
Keys
Bladder
Helene Felice 11
Shell-based support structureConcept
12/10/2014
• Shell-based support structure often referred as “bladder and keys” structuredeveloped at LBNL for strain sensitive material
Displacement scaling 30
Cool-down
Cool-down
Keys
Bladder
Helene Felice 12
Shell-based support structureConcept
12/10/2014
Displacement scaling 30
Energized
• Shell-based support structure often referred as “bladder and keys” structuredeveloped at LBNL for strain sensitive material
Lorentz forces
Cool-down
Keys
Bladder
cold
Room temperature
Collaring process- Courtesy of Paolo Ferracin
With shell structure
Support structure allowing fine tuning of the
Shell-based support structureKey features
• Gradual application of the preload: no overshoot
• Tunable preload– During assembly– In between tests
• Reversible assembly process– Allowing replacement of a defective coil if needed
• Correlation between models and strain gauges measurements
12/10/2014Helene Felice 13
Outline
• Shell-based support structure concept• Exploring the limits
– TQ high stress • Step-by-step technology demonstration
– Design optimization– Length
• QXF support structure– Main features
12/10/2014Helene Felice 14
Stress limits: defining an acceptable rangeTQS03 program
12/10/2014Helene Felice 15
CONDUCTOR• OST RRP 108/127 strand• High RRR• 54 % Cu fraction• Jc (12T, 4.3 K) 2770 A/mm2
• 27 strands cable• 1.26 mm mid-thickness bare• 10 mm width bare• 0.125 mm insulation
TQS03parameters
4.3 K 1.9 K
Iss (kA) 13.2 14.5
Bpeak ss (T) 12 13
Gss (T/m) 234 254
4 tests: TQS03 a, b, c and d
• performed with variable pre-stress• TQS03a: 120 MPa• TQS03b: 160 MPa• TQS03c : 200 Mpa• TQS03d: 120 MPa
• supported by ANSYS analysis
12/10/2014Helene Felice 16
Strain gauges location
In boxes: sig theta measured
Add predicted on box
-1500
-1000
-500
0
500
1000
1500
2000
2500
3000
300K 4.2 K 300K 4.2 K 300K 4.2 K 300K 4.2 K
TQS03a TQS03b TQS03c TQS03d
e q(me)
shell T meas
Pole T meas
shell T ANSYS
Pole T ANSYS
-160 MPa
-120 MPa-190 MPa
-110 MPa
200MPa180MPa
160MPa 160MPa
Good agreement between measurements and ANSYS prediction
12/10/2014Helene Felice 17
78
80
82
84
86
88
90
92
94
96
98
100Fr
acti
on o
f I ss(%
)
TQS03a
TQS03b
TQS03c
TQS03d
4.3 K 1.9 K 4.3 K
93 %
91 %
88 %
88 %
~ 11.6 / 12.8 kA
• Only 5 % degradation from TQS03a to TQS03c• TQS03d did not recover => Permanent
degradation
~ 12 / 13.2 kA
~ 12.3 / 13.5 kA
Helene Felice 18
Strain gauge data during excitation
12/10/2014
Strain gauge
• conclusion
TQS03a
TQS03b
TQS03cPreload increase
Preload increase
Correlation between preload levels and magnet performance allowed the definition of a safe range of transverse stress in Nb3Sn coils
Outline
• Shell-based support structure concept• Exploring the limits
– TQ high stress • Step-by-step technology demonstration
– Design optimization– Length
• QXF support structure– Main features
12/10/2014Helene Felice 19
From TQ to HQDesign optimization
12/10/2014Helene Felice 20
TQ LQ
• No alignment features
Plot of stress along the length
• Optimization of the design• load key positon• Pad extremity in
stainless steel to lower peak field in the end
• Implementation of alignment features from pad to shell
From TQ to HQDesign optimization: key position optimization
12/10/2014Helene Felice 21
TQ - 90 mm aperture- 12 T peak field - 240 T/m
- Fq Layer 1 = -1.5 MN/m- Fq Layer 2 = -1.02 MN/m
LQ- 90 mm aperture- 12 T peak field - 240 T/m
- Fq Layer 1 = -1.5 MN/m- Fq Layer 2 = -1.02 MN/m
-100 MPa
-187 MPa
-85 MPa
-171 MPa
Key
optimization
=> Optimization of the key position to improve stress distribution
20 MPa 20 MPa
From TQ to HQDesign optimization
12/10/2014Helene Felice 22
TQ LQ HQ
• No alignment features
• Cross-section optimization considering force distribution between layers
• Alignment features between coil and pads: aluminum collars and key
• Optimization of the design• load key positon• Pad extremity in
stainless steel to lower peak field in the end
• Implementation of alignment features from pad to shell
From TQ to HQDesign optimization: key position optimization
12/10/2014Helene Felice 23
TQ - 90 mm aperture- 12 T peak field at 4.3 K- 240 T/m
- Fq Layer 1 = -1.5 MN/m- Fq Layer 2 = -1.02 MN/m
LQ- 90 mm aperture- 12 T peak field at 4.3 K- 240 T/m
- Fq Layer 1 = -1.5 MN/m- Fq Layer 2 = -1.02 MN/m
HQ - 120 mm aperture- 14 T peak field at 4.3 K- 200 T/m
- Fq Layer 1 = - 2.1 MN/m- Fq Layer 2 = - 2.6 MN/m
-100 MPa
-187 MPa
-85 MPa
-171 MPa
MPa
MPa
Xsection
optimizationKey
optimization
=> Improvement of the cross-section to avoid layer 2 overloading
20 MPa 20 MPa MPa
Stress in HQ
12/10/2014Helene Felice 25
Adresses:- Stress distribution
- 2D and 3D- Pad ss and iron- Ground for MQXF stress level
Outline
• Shell-based support structure concept• Exploring the limits
– TQ high stress • Step-by-step technology demonstration
– Design Optimization– Length
• QXF support structure– Main features
12/10/2014Helene Felice 26
1st long shell based structure:the Long Racetrack LR
12/10/2014Helene Felice 27
• LRS01: full length shell• Friction limits the shell contractions
• Central part locked• Strain at 4.5 K consistent with 0.2 friction
model results• During excitation e.m. forces induced
slippage
Magnet parameters
( )( )zE ee
21
Helene Felice
Impact of shell segmentation
12/10/2014 #28
• LRS01– High meas. axial strain meas.– Effect on azimuthal stress
• LRS02 (with segmented shell) – Reduced axial strain
LRS
LQS
LRS01
LRS02
( )( )zE ee
21
Helene Felice 29
Length demonstration on a cos2 q magnet:the Long Quad LQ
12/10/2014
• 90 mm aperture coils with Ti poles • Iron pads, masters, yokes, Al shell• Pre-load with bladders and keys• TQ coil scale-up
• LQS01-2 Short-sample limits (4.5 K – 1.9 K)– Gss: 240 T/m – 267 T/m
– Iss: 13.8 kA – 15.4 kA– Peak field: 12.3 T - 13.6 T
• LQS03 Short sample limit
– -Gss: 227 T/m – 250 T/m
– Iss: 12.9 kA – 14.4 kA
– Peak field: 11.5 T - 12.8 T
• End support: plate and rods• Magnet/coil length: 3.7/3.4 m
30
Preload for 240 T/m: 471 kNsz and ez at 300 K- target (3D): +88 Mpa (178 kN)
+455 mesz and ez at 4.3 K- target (3D): + 239 MPa + 1138 me
Rod
0
10
20
30
40
50
60
70
-0.2 0 0.2 0.4 0.6 0.8 1
End
cont
act p
ress
ure
(MPa
)
Fem/Fem_240T/m
293 K
End
Con
tact
pr
essu
re (
Mpa
)
Preload for 260 T/msq and eq at 300 K - target (3D): -82 MPa
-580 mesq and eq at 4.3 K - target (3D): -157 MPa -1031 me
s q (MPa)
Pole
Mechanical AnalysisTypical Stress distribution
12/10/2014Helene Felice
Preload for 260 T/msq and eq at 300 K- target (3D): + 56 MPa
+ 750 mesq and eq at 4.3 K- target (3D): + 183 MPa +2080 me
s q (MPa)
Shell
NO gap
-198-180-162-143-125-107-88-70-51-33
149156163170177184191198208212
Helene Felice 32
Production readiness:Accommodating coil size variation
12/10/2014
Expected
measured
shell Strain Gauge
coil Strain Gauge
Nominal
padPole StrainGauge
LQS01a
Nominal Oversized
padPole StrainGauge
92 % at 4.5 K
LQS01aLQS01b
Outline
• Shell-based support structure concept• Exploring the limits
– TQ high stress • Step-by-step technology demonstration
– Alignment features– Length
• QXF support structure– Main features
12/10/2014Helene Felice 33