larp collaboration meeting tqs01 - progress
DESCRIPTION
LARP Collaboration Meeting TQS01 - Progress. Shlomo Caspi Lawrence Berkeley National Laboratory April 26-28, 2006. Outline. TQS01 - Construction Design and Analysis Preliminary test results. Statement of work – TQS01. One of the main objectives: - PowerPoint PPT PresentationTRANSCRIPT
LARP Collaboration Meeting TQS01 - Progress
Shlomo Caspi
Lawrence Berkeley National Laboratory
April 26-28, 2006
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Outline
• TQS01 - Construction
• Design and Analysis
• Preliminary test results
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Statement of work – TQS01
One of the main objectives:
• Compare the magnet performance with the Compare the magnet performance with the design parametersdesign parameters.
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TQS01 Main Features
• A 2 layers Nb3Sn Quadrupole
• A 10mm wide 27 strand cable. (0.7mm MJR strand)
• Short sample 4.2K (B,G,I) : 11.2T, 220T/m, 12.3kA
• Accumulated Lorentz stress : S_theta=-123MPa
• Accumulated axial force (4 quadrants) : F_z=350kN
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2 layers
FillerKeys
4 pads
Bladder
Yoke
Aluminum shell
TQS01
•No collarsNo collars•BladdersBladders for coil azimuthal pre-stress for coil azimuthal pre-stress
B ~ 12 T, stress: 150 MPa, total axial force = 350 kN
The structure and assembly is different from any previous magnet of this kind
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TQS01 – Construction
• Coil winding• Coil reaction• Instrumentation• Impregnation• Coil sub-assembly• Structure sub-assembly• Final assembly and pre-stress
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Coil winding at FNAL
• A double layer
• Bronze island and end spacers
• Layer 1 wound on a mandrel and cured using a binder.
• Layer 2 wound on top of layer 1 and then cured.
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Coils Shipped to LBNL
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Prepare for Reaction
Two coils reacted together
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Into Reaction Oven
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Reaction Cycle (Coils 7 and 8)
•72 hr at 210 C
•48 hr at 400 C
•48 hr at 640 C
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Post-Reaction
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Coil - Instrumentation
Voltage tap
Strain gauge
Inner layer trace
Strain gauges and voltage tap attached to trace
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Ready for Impregnation
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Impregnation
Coil placed into impregnation
chamber
Controller
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Impregnated Coils
Strain gauges placed on layer 1 island
Voltage traces
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Coil-pack sub-assembly
Coil-pack is a sub-assembly of coils pads and fillers
Coil Pack is assembled, squared and bolted.
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Structure sub-assembly, shell, yoke and intermediate gap keys
• 20” OD x 18” ID x 40”long, 6061-T6 aluminum shell, precision machined.
• 1018 steel yoke laminations, 2”-thick
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SHELL & YOKE SUB-ASSEMBLY,cont’d
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Final assembly
• Mating the coil pack with the shell & yoke sub-assembly.
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End Support
bullets
End plate (89 mm thick)
Axial Aluminum rods (44 mm dia.)
Strain gauges
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End plates assembly
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Axial load components
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Axial Pre-stress
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Axial Pre-stress, cont’d
• 25 -Ton hydraulic actuator (9500 psi)
• Axial Loading Rig
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Azimuthal pre-stress (bladder operation)
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Complete assembly – return end
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End splices
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End splices (pizza box)
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TQS01 lowered into cryostate
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Outline
• TQS01 – Construction
• TQS01 – Design and AnalysisTQS01 – Design and Analysis
• TQS01 – Peliminary results (cool-down)
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Integrated analysis and simulations
CAD (engineering)
FEM (magnetic)
FEM structure multi-physics
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3D mechanical analysis: Lorentz forces
• ANSYS• x, y, and z coordinates of
each coil element center
• OPERA• Computation of J x B
(N/mm3) at each x, y, and z coordinate
• ANSYS• Computation of J x B Vel
(N)• Final force applied to each
coil node
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TOSCA
Layer 1 |B|=12.15T in SS
Layer 2 |B|=12.0T END
I=13.5kA,1.9K
Maximum field:
Layer 1 - straight section
Layer 2 - end
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Structural Analysis - ANSYS
Steps:
Assembly.Assembly.
Cool-down.Cool-down.
Lorentz forces 10-15 kALorentz forces 10-15 kA
Load Cases:• Combinations of azimuthal and axial pre-stress• Model with and without friction or glued• Blocked turns and individual turns
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ANSYS model – straight section
Rule 1 - No azimuthalRule 1 - No azimuthal separation at the poleseparation at the pole
1
2
3
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ANSYS model – coil ends
Island End-shoeSpacer
Rule 2 - No axial separation in the endRule 2 - No axial separation in the end
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Structure – Shell - azimuthal
Shell and yoke mu=0.6, all other
surfaces with friction, mu=0.2
SS 4.2K SS 1.8K
Low assembly pre-stress
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Structure – Axial rods
Low assembly pre-stress
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Azimuthal stress in layer 1 (with friction)
± range
Short sample 4.2K
Short sample 1.9K
4.2 K
14kA
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Training Mechanism
Straight sectionStraight section
• Axial tensile strain in the pole island held by friction releases when the coil pulls away due to insufficient azimuthal pre-stress.
End sectionEnd section
• Sliding and tarring between the coil and the island due to insufficient axial pre-stress.
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Island axial strain- straight section
abrupt or slow
release of strain
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release of axial strain
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Ends and axial Lorentz Force
Lorentz axial force 351/413 (kN)
Applied axial force 800 (kN)
(with friction)
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0 friction, limited axial load
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Island axial displacements- end section
170 µmIsland
displacement
(with friction)
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Outline
• TQS01 – Construction
• TQS01 – Design and Analysis
• TQS01 – Preliminary test resultsTQS01 – Preliminary test results
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Strain Measurements
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Cool-down
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Rods – measured cool-down stress
4.3K4.3K
200K200K
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Shell – measured cool-down stress
E
1 2 z
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Shell – measured cool-down stress
4.3K4.3K
200K200K
E
1 2 z
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Island – measured cool-down stress
•Axial tensile stress
•Compressive azimuthal stress
E
1 2 z
4.3K4.3K
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Ratcheting During Cool-Down
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Shell ratcheting during cool-down
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Coil ratcheting during cool-down
ratcheting in theta
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Coil ratcheting during cool-down
Minimum /no ratcheting in Z
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Excitation
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TQS01 4.45k Training
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Layer 1 center island
Lay1-Lay2 ramp
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Coil Center Details
SG-Z SG-Theta
Start of L1-L2 rampIsland discontinuity
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Coil End Details
SG-Z
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Island azimuthal strain during excitation
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Island strain in θ, magnet center
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Island strain in Z, magnet center
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Island axial strain (center)
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Island Stress
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Island Stress over many quenches
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Island strain in Z, lead end
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Island axial strain (end)
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Island axial strain (end)
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StructureShell in θ, z
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Shell azimuthal strain
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Shell axial strain
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Shell stress
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Shell stress
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StructureRods in z
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Rods Stress
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Rods Stress
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Summary
• The most “engineered” magnet we ever built.
• Analyzed every component from assembly through cool-down and excitation and pushed Nb3Sn technological to new limits.
The design expectations are:
• Reach short sample prediction (field, current, stress)
• Get there with minimum training
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Summary …
• First quench – Q1 at 80% of ss (176 T/m)
• Plateau – Q12 at 86% (190 T/m)
• Thermal cycle on TQS01
• Data reduction and analysis:• Strain gauge measurements• Quench locations• Refine ANSYS analysis
• If evidence suggests a problem in coil 6 ramp area:• Replace coil 6 with spare and retest• Section ramp area