CNGS Horns : Status 8 nov. 2003 NBI 2003 KEK, Japan 7-11 nov. - - PowerPoint PPT Presentation

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CNGS Horns : Status 8 nov. 2003 NBI 2003 KEK, Japan 7-11 nov. - - PowerPoint PPT Presentation

May 21, 2023 585 likes •818 views

CNGS Horns : Status 8 nov. 2003 NBI 2003 KEK, Japan 7-11 nov. 2003 NBI 2003 - CNGS Horns Status 1 Presented by Sandry Wallon CNGS Horns : Status CONTENT 1 .O u t l i n e o f t h e c o n t r i b u t i o n 2 .D

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NBI 2003 - CNGS Horns Status Presented by Sandry Wallon

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CNGS Horns : Status

8 nov. 2003

NBI 2003 – KEK, Japan 7-11 nov. 2003

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NBI 2003 - CNGS Horns Status Presented by Sandry Wallon

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CNGS Horns : Status

CONTENT 1 .O u t l i n e

  • f

t h e c

  • n

t r i b u t i

  • n

2 .D e s i g n & s t u d i e s 3 .M a n u f a c t u r e & c h e c k i n g s 4 .M

  • u

n t i n g & a d j u s t m e n t s 5 .S u m m a r y

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NBI 2003 - CNGS Horns Status Presented by Sandry Wallon

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  • 1. O

u t l i n e

  • f

t h e c

  • n

t r i b u t i

  • n

French contribution

P i

  • n

s a n d k a

  • n

s f

  • c

u s e d b y 2 m a g n e t i c h

  • r

n s t

  • w

a r d G r a n S a s s

  • 2 horns (included 1 spare horn)
  • 1 reflector
  • 2 cooling systems
  • 2 strip lines w/ fast coupling system
  • 2 sets of adjustable supports
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NBI 2003 - CNGS Horns Status Presented by Sandry Wallon

4

  • 2. Design & studies

Double pulses within 50 ms Pulse duration : 6 ms (horn) 13 ms (reflector) 6 s cycle during 4 years (2 107 pulses) 150 kA (peak), 5000 ARMS Toroidal B field : 1.9 T max. 7.5 m long 1600 kg of aluminium alloy (+ ceramic, stainless steel, …) 7.5 m long 2200 kg

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NBI 2003 - CNGS Horns Status Presented by Sandry Wallon

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  • 2. Design & studies

Full 3D design Horn

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NBI 2003 - CNGS Horns Status Presented by Sandry Wallon

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  • 2. Design & studies

Other equipement Fast Coupling System & striplines inside chamber / gallery

Set of 3 adjustable supports

Fast Coupling System (FCS) Strip lines Not shown : cooling system Striplines and FCS new design

⇒ Worker’s protection during loosening / tightening FCS (shielded chicane) ⇒ Better confidence in FCS functionality

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NBI 2003 - CNGS Horns Status Presented by Sandry Wallon

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  • 2. Design & studies
  • Misc. studies done to

guaranty functionalities

(especially for horn’s inner conductor)

  • Thermal : Deformation & Stress.
  • Static : Straightness.
  • Stability : Buckling.
  • Dynamic : Fatigue-corrosion (4 years lifetime requested).

Status Done

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NBI 2003 - CNGS Horns Status Presented by Sandry Wallon

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  • 2. Design & studies

⇒ material behavior ⇒ thermal expansion, stresses

Thermal study

Water curtain falling

  • nto inner conductor

Heat load (inner cond.)

  • 13 kW (Joule losses)
  • 5 kW (radiation)

coeff convection

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NBI 2003 - CNGS Horns Status Presented by Sandry Wallon

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  • 2. Design & studies

∆T = 5 °C ∆T = 8 °C ∆T = 2 4 °C ∆T = 3 3 °C T

m

̃ 4 °C

  • 0.75 <∆Ldyn< 0.75 mm

(thanks to a 1.2 mm enforced

  • displ. [∆Lm=1.2 mm])

1.5 mm ‘dynamic’ thermal expansion enable by thin flange Cyclical thermal stress

  • 10 < σ < 10MPa

stress

Thermal study

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NBI 2003 - CNGS Horns Status Presented by Sandry Wallon

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  • 2. Design & studies

σecr = 54 MPa (mode 2) [1]

axi-symmetric

vibration mode 1

(140 Hz) movie Pt 1 (mode 1; 1+2)

D y n a m i c s t u d y ⇒ fatigue strength

axi-symmetric

vibration mode 2

(360 Hz) movie Pt 2 (mode 2; 1+2) Pt 3 (mode 1+2)

[1] : From Marek Kozien’s Ansys study (Cern / Cracow university)

mode 1, mode 2, mode 4

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NBI 2003 - CNGS Horns Status Presented by Sandry Wallon

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  • 2. Design & studies

F a t i g u e s t r e n g t h

thermal + mechanical stresses : we are below the envelope curve Warning Infinite lifetime do not exist!

fatigue-corrosion, SN curve 6082

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NBI 2003 - CNGS Horns Status Presented by Sandry Wallon

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  • 3. Manufacture & checkings

Large parts

  • uter conductor

electrical connection

Status

Horns 1 et 1b : done

Reflector : done

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NBI 2003 - CNGS Horns Status Presented by Sandry Wallon

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  • 3. Manufacture & checkings

Inner conductors

2 inner conductors after EB welding Rigid flange checking

Production status Horns 1 & 1b : done Reflector : in progress

(large) Electrons Beam welding machine

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  • 3. Manufacture & checkings

inner conductors

Horn flanges’ checkings (after machining) → Ultrasonic → X ray → geometrical Shot penning Horn inner conductors’ checkings (after welding) → X ray (for welds) Horn tronconical parts’ checkings

(after machining)

→ Dye penetrant Reflector : cheaper processes used

  • rolled & welded sheet
  • TIG welding
  • dye penetrant (welds)
  • 3D checking

Status Horns 1 & 1b : done

Reflector : production in progress 2 inner conductors after EB welding

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NBI 2003 - CNGS Horns Status Presented by Sandry Wallon

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  • 3. Manufacture & checkings

8 m long ‘bench’ clamp flanges intermediate supports Outer surface axis checking (straightness) Inner conductor (final) checking Spec required : 1 mm shape tolerance

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  • 3. Manufacture & checkings

Inner conductor (final) checking (as done)

  • uter surface axis checking (straightness)

Job done at Cern by

  • Ahmed Cherif (3D machine)
  • Dominique Missiaen (laser tracker)

Status Done

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  • 4. Mounting & adjustements

Horn’s mounting BAD surprise

There’s a inner cond. non-conformity 2 sets of grooves are uncorrectly located

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NBI 2003 - CNGS Horns Status Presented by Sandry Wallon

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  • 4. Mounting & adjustements

Horn’s inner cond. non-conformity Actions

→ Crisis meeting! → Solution proposals → 3D design & drawing jobs → Mini prod. readiness review → Electrical insulators order → New spider manufacture → Outer conductor machining (new spiders locations) ⇒ Σ = 2.5 months

→ Find where do the mistake come from? ⇒ CAD (design) used as CAD (drafting) Other gift : Inner cond was designed with Euclid CAD soft, other parts and assemblies with Catia CAD soft!

Status Done

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  • 4. Mounting & adjustements

Inner conductor straightness adjustment 1. Put a self centering probe inside inner conductor 2. Check probe position 3. Adjust wires tensile force until to find correct alignment 4. repeat previous job for 2 others cables sets Status Will be performed at (by) Cern within 2004 Warning Former picture To be refreshed

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  • 4. Mounting & adjustements

Centering stems & electrical connection adjustments Centering stems :

position adjustment / inner conductor axis

Electrical connection :

position adjustment / inner conductor axis

Warning Former picture To be refreshed How to achieve interchangeability between horn and spare horn?

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  • 4. Mounting & adjustements

Horn axis adjustment

  • 2. Tighten / loosen 2 M12 screws

(bottom screws) ⇒ vertical displ. ± 20 mm (top screws) ⇒ lateral displ. ± 20 mm

  • 1. Loosen FCS / open strip lines /

Unplug strip lines NB connection plates to be machined Warning Former picture To be refreshed

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  • 5. Summary

Horn manufacture : done, except FCS (production review within 1 month) Reflector manufacture : done, except inner conductor (to be deliver within january 2004) Non-conformity trouble : solved Adjustable support : jack received, other parts to be manufactured FCS & Striplines : design to be completed (production review within 1 month) Cooling system : ready for production review? Mechanical tests in progress (S. Rangod, G. Maire) : Electrical tests (horns, reflector, FCS) within 2004 picture