larp phase ii secondary collimator rc1 prototype engineering status 6/21/06
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2006-06-21Coll Eng E Doyle 1/18
LARP Phase II Secondary Collimator RC1 Prototype Engineering Status
6/21/06
Jaw-hub-shaft concept - continued
Permanent deformation (elastic/plastic analysis)
2006-06-21Coll Eng E Doyle 2/18
Overview
• Review– Baseline jaw– Central stop Concept
• Discuss RC1 baseline deflection reference• Refine baseline
– Shorter pitch cooling helix– Solid core
• New jaw-hub-shaft concept• Eliminate central stop?• Plastic deformation
2006-06-21Coll Eng E Doyle 3/18
Collimator TCSM.A6L7 Cooling scheme Helical Axial (36o)
# channels 1 2 Diam (m) .008 .006 Velocity (m/s) 3 3
Cooling
Total flow (l/min) 9 10 SS Power (kW) 11.7 Beam heat Trans Power (kW) 58.5
Jaw peak 86.5 91.5 Cooling chan. peak 68.3 69.7
SS
Water out 36.0 36.1 Jaw peak 231 223 Cooling chan. peak 154 130
Temp (C )
Trans
Water out 43.6 47 SS 394 107 Deflection (um) 4 Trans 1216 778 SS 43 75 Eff. length (cm) 5 Trans 24 31
Exceeds Allowed Deflections
All temperature simulations based on 20C supply. For CERN 27C supply add 7 to all temperature results. CERN max water return temp 42C
Exceeds spec, or other possible problem as noted
Review: Baseline Jaw Performance (deflections referred to edge of jaw - Note this is not a realistic mounting possibility)
Baseline: hollow Cu, 25mm wall, helical cooling - 5cm pitch
VV
2006-06-21Coll Eng E Doyle 4/18
Two concepts for reducing deflection
• Central aperture stop
• Separate shaft and jaw
2006-06-21Coll Eng E Doyle 5/18
86C
Bending exceeds 25um spec => Compromise:
Central aperture stop controls deflection - causes jaw to deflect away from beam – Note: this is idealized stop
x=394 m
Spec: 25m
support
support
Steady State operation (End supports as modeled)
More realistic: shaft support
-Swelling toward beam
-Bending toward beam
Idealized Central Aperture Stop
-Swelling neutrallized
-Bending neutralized
2006-06-21Coll Eng E Doyle 6/18
Leaf springs allow jaw end motion up to 1mm away from beam
RC1 Concept as presented to reviewers: Flexible end supports with central aperture stop
Stop prevents thermal bowing of jaws from intruding on minimum gap
Local swelling not controlled
2006-06-21Coll Eng E Doyle 7/18
Real aperture stop allows some swelling
Stop hidden out of beam’s reach at 45o
Swelling not fully neutralized – note bulge of hot region between stop and aperture.
Peak temperature due to beam heating
StopV
2006-06-21Coll Eng E Doyle 8/18
Jaw-hub-shaft - Eliminate Central Stop?
1. Hub acts as a heat sink near peak temperature location, lowering peak temperature, reducing gradient and bending.
2. Both ends of jaw deflect away from beam. (Note: swelling component of deflection is not corrected - ~ the same as for stop @ 45o.)
3. Max deflection toward beam reduced if the shaft deflection can be minimized
4. Cooling coils embedded in I.D. of jaw.
shaft jawhub
2006-06-21Coll Eng E Doyle 9/18
Advances since RC1 Baseline
solid core more cooling
2006-06-21Coll Eng E Doyle 10/18
shaft end
deflection reference jaw edge shaft central stop central stopbaseline (25mm) 394 426 36 390refined baseline (25mm) - 238 24 214jaw-hub-shaft (25mm) - 100 48 52
baseline (25mm) 1216 1260 97 1163refined baseline (25mm) - 853 76 777jaw-hub-shaft (25mm) - 339 179 160
jaw max toward beam
Evolution of jaw-hub-shaft25mm deep cooling tubes
SS 1hr beam
Transient 10sec @12min beam
RC1 – not a practical support scheme
More
realistic
Note reduced shaft end deflection – a positive result if stop is used
Next for jaw-hub-shaft:
Alternative materials to reduce shaft deflection
2006-06-21Coll Eng E Doyle 11/18
Simple support, deflections referred to jaw edge or shaft
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deflections referred to jaw edgeCu, 136x71x950- , cooling 25mm deep, 5cm pitch 11.7 86.5 394 58.5 231 1216 RC1 baseline
Cu, 136x11x950- , solid, cooling 25mm deep, 5cm pitch 11.7 75.5 253 58.5 209 919 baseline + solid
Cu, 136x11x950- , solid, cooling 25mm deep, 2cm pitch 11.7 65.7 202 58.5 195 813Cu, 136x11x950- , solid, cooling 10mm deep, 2cm pitch 11.7 54.3 136 58.5 159 606 baseline + solid, shallow, 2p
Simple support, deflections referred to shaftCu, 136x71x950- , cooling 25mm deep, 5cm pitch 11.7 86.5 426 58.5 231 1260 RC1 baseline
Cu, 136x11x950- , solid, cooling 25mm deep, 5cm pitch 11.7 75.5 291 58.5 209 962 baseline + solid
Cu, 136x11x950- , solid, cooling 25mm deep, 2cm pitch 11.7 65.7 238 58.5 195 853 refined baseline
Cu, 136x11x950- , solid, cooling 10mm deep, 2cm pitch 11.7 54.3 171 58.5 159 646 base + solid, shallow, 2p
Cu, solid shaft, 25mm, 2cm pitch 11.7 66.3 100 58.5 197 339 jaw-hub-shaft
Cu, solid shaft, 10mm, 2cm pitch 11.7 54.7 78 58.5 160 280Cu, super invar shaft, 25mm, 2cm pitch 11.7 67.4 90 58.5 199 266 super invar shaft
Cu, tungsten shaft, 25mm, 2cm pitch 11.7 66.8 88 58.5 198 270 tungsten shaft
Cu, sst shaft, 25mm, 2cm pitch 11.7 67.3 132 58.5 199 368 sst shaft
Cu, Be shaft, 25mm, 2cm pitch 11.7 66.7 112 58.5 198 368 Be shaft
Glidcop AL15, solid, cooling 25mm dp, 2cm pitch 11.7 68.6 103 58.5 205 348 all Glidcop
SS @ 1 hour beam life transient 10 sec @ 12 min beam life
Alternative Shaft MaterialsShaft supported case - Slight Improvement
Deflection is combo of bending & swelling
2006-06-21Coll Eng E Doyle 12/18
Spring-supported ends, center stop at 45 degrees, deflections referred to stop
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jaw
Cu, 136x71x950- , cooling 25mm deep, 5cm pitch 11.7 86.5 36 58.5 231 97 RC1 baseline
Cu, 136x11x950- , solid, cooling 25mm deep, 5cm pitch 11.7 75.5 26 58.5 209 83 baseline + solid
Cu, 136x11x950- , solid, cooling 25mm deep, 2cm pitch 11.7 65.7 24 58.5 195 76 refined baseline
Cu, 136x11x950- , solid, cooling 10mm deep, 2cm pitch 11.7 54.3 22 58.5 159 64 baseline + solid, shallow, 2p
Cu, solid shaft, 25mm, 2cm pitch 11.7 66.3 48 58.5 197 179 jaw-hub-shaftshaft
Cu, solid shaft, 10mm, 2cm pitch 11.7 54.7 34 58.5 160 135Cu, super invar shaft, 25mm, 2cm pitch 11.7 67.4 48 58.5 199 192 super invar shaft
Cu, tungsten shaft, 25mm, 2cm pitch 11.7 66.8 47 58.5 198 184 tungsten shaft
Cu, sst shaft, 25mm, 2cm pitch 11.7 67.3 50 58.5 199 180 sst shaft
Cu, Be shaft, 25mm, 2cm pitch 11.7 66.7 46 58.5 198 179 Be shaft
Glidcop AL15, solid, cooling 25mm dp, 2cm pitch 11.7 68.6 51 58.5 205 186 all Glidcop
SS @ 1 hour beam life transient 10 sec @ 12 min beam life
Alternative Shaft MaterialsCentral stop-supported case - No Improvement
Note: values in table manually adapted from simulation results based on jaw edge or shaft end supports. Stop located in mid-jaw at 45 degrees from point closest to beam.
2006-06-21Coll Eng E Doyle 13/18
shaft end deflection eff lengthdeflection reference jaw edge shaft stop stop n/a n/abaseline (25mm) 394 426 36 390 394 0.43refined baseline (25mm) - 238 24 214 202 0.63jaw-hub-shaft (25mm) - 100 48 52 221 0.51
baseline (25mm) 1216 1260 97 1163 1216 0.24refined baseline (25mm) - 853 76 777 913 0.31jaw-hub-shaft (25mm) - 339 179 160 881 0.25
jaw max toward beam
Evaluate jaw-hub-shaft25mm deep cooling tubes
Transient 10sec @12min beam
SS 1hr beam
With stop
con: 2x deflection
pro: 75% reduction of shaft motion
Shaft support only
con: 4x deflection
pro: simpler mechanism, same control architecture as Ph I
4x2x
Note: deflection means deviation from straight (in um). Eff length is length of jaw (in m) deflected <100 um compared to maximum deflection point.
New Baseline
2006-06-21Coll Eng E Doyle 14/18
Permanent DeformationInitial condition: 1 hr beam lifetime heating rate. Transient: 10 seconds heating at 12min beam lifetime rate followed by 50 seconds cooling.
Copper Glidcop AL15
2006-06-21Coll Eng E Doyle 15/18
Permanent Deformation
Permanent Deflection – deviation from straight (um)
Refined baseline 73
All Cu shaft-hub-jaw 62
All Glidcop AL15 shaft-hub-jaw ~0
Permanent bending of jaw after one transient heating cycle. Deflection is concave as seen from beam. Glidcop AL15 effectively prevents plastic deformation.
2006-06-21Coll Eng E Doyle 16/18
Further refinements
• Optimize hub length, location
• Hub region solid Cu, two stub shafts of alternative material, butted to hub
• Shallow cooling tubes (~15mm)
• Glidcop only where necessary – outer radii
2006-06-21Coll Eng E Doyle 17/18
Xtra Slide
2006-06-21Coll Eng E Doyle 18/18
shaft end deflection eff lengthdeflection reference jaw edge shaft stop stop n/a n/abaseline (25mm) 394 426 36 390 394 0.43refined baseline (10mm) - 171 22 114 135 0.78jaw-hub-shaft (10mm) - 78 34 44 224 0.51
baseline (25mm) 1216 1260 97 1163 1216 0.24refined baseline (10mm) - 646 64 542 604 0.36jaw-hub-shaft (10mm) - 280 135 145 800 0.25
jaw max toward beam
Evolution of jaw-hub-shaft25mm =>10mm deep cooling tubes
shaft end deflection eff lengthdeflection reference jaw edge shaft stop stop n/a n/abaseline (25mm) 394 426 36 390 394 0.43refined baseline (25mm) - 238 24 214 202 0.63jaw-hub-shaft (25mm) - 100 48 52 221 0.51
baseline (25mm) 1216 1260 97 1163 1216 0.24refined baseline (25mm) - 853 76 777 913 0.31jaw-hub-shaft (25mm) - 339 179 160 881 0.25
jaw max toward beam
SS 1hr beam
Transient 10sec @12min beam
SS
Transient
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