Integrated Super Modules + New Prototypes Motivations Motivations - - PowerPoint PPT Presentation

CERN, AUW the 11th of Nov, 2010 1

Integrated “Super Modules” + New Prototypes

On behalf of the team @ University of Geneva: A.Clark, G.Barbier, F.Cadoux, D.Ferrère, S.Gonzalez-Sevilla, C.Husi, M.Weber And KEK: Y. Ikegami, S. Terada, Y. Unno

Motivations Key features for Super Modules (SM) CAD description and Material list (X0) Prototype program 2010-2011 Integration to the structures and FEA’s Motivations Key features for Super Modules (SM) CAD description and Material list (X0) Prototype program 2010-2011 Integration to the structures and FEA’s

CERN, AUW the 11th of Nov, 2010 2

Motivations [1]

• A. Viability was proven of the End insertion / 2 types (STAVE and Super Modules SM1.0)

The key idea was to perform an OPTIMISATION on Super Module approach.

Module assembly v1 (prior Insertion) Super Module (version SM1.0)

Z0 Z0 Z1200

free along Z Module assembly v1 (prior Insertion) Clamping point

Z1200

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Motivations [2]

Module assembly v1 (prior Insertion)

STAVE Design acc. to Geneva concept (as shown in November 2009 with a demonstrator, see presentation: STAVE_Nov09UNIGE.ppt)

Locking mechanism at Z0

We widely benefited from our STAVE proto development… which led us to adapt some ideas

• n the Super Module “Optimized version” (SM2.0)…

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Motivations [3]

• B. Immediate goal: benefit from the “8 Modules assembly” used for testing ..and to

make them compatibles on a light structure in a coherent way

Multi-purpose jig:

• Pipe and block assembly
• Module mounting
• Service mounting
• Transport, storage and Tests

CAD pictures taken up from Didier’s talk (thanks to Maarten Weber for all this detailed development)

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Key features on Super Modules Concept

• Based on a modular concept (modules, cooling, local support, service bus, SMC,…)
• Full module coverage in Z due to overlaps (shorter barrel structure)
• Rework is a strong feature and can be done up to the commissioning
• Good thermal performances (for both CO2 and C3F8…

and the choice of coolant could be done late / design development!)

• The sharing of work can be optimized and spread over several institutes: support,

Modules, Cable bus, SMC...and testing at intermediate steps (Modules, SMC)

• An easy handling due to the CFRP mechanical frame
• And last but not least, it allows a free stress insertion for every position in Phi

KEY POINTS KEY POINTS

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CAD description [1]

Complete integrated CAD view of the SM2.0 (12 modules assembled thru the cooling block) Envelope for service bus and connections (still to be optimized)

Z0 Z1200

Service Module SMC at the end From the end view… Enveloppe for service bus and connections Link to structures

Thanks to Gerard Barbier for this optimization work Z600

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CAD description [2]

Starting from a bare jig… …then, populated with cooling plates Assembly main steps (based on “8 modules” project)

1 2 3 4

…1 out of 2 modules fixed to the cooling plate …assembly completed with the rest of modules (after stand rotation)

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CAD description [3]

Complete integrated CAD view of the SM2.0 (12 modules assembled thru the cooling block) Possible link to service bus CFRP Guiding pipes Central CFRP pipe Connector or wire bonding Cooling pipe

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Material list summary

Estimate of the X0 number

2.58

779.87 Total 1.82 518.64 module 0.31 60.348 Cable bus 0.45 200.882 LS for 12 MODULES % X0 Weight [g]

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Prototype program 2010-2011 [1]

Our goal is to: Develop 2 full length prototypes What means to build jigs and frames for assembly and part manufacturing (see next)

• 1 for Testing (sagging, …)
• 1 for Module assembly and further optimizations

Our goal is to: Develop 2 full length prototypes What means to build jigs and frames for assembly and part manufacturing (see next)

• 1 for Testing (sagging, …)
• 1 for Module assembly and further optimizations

Support (CFRP) Cooling Plates x6 (still to be prototyped) CFRP Backbone (key part!) Every sub part assembled with epoxy (need of several jig)

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Prototype program 2010-2011 [2]

Cross beams processing (in Carbon Fiber) Cross beams processing (in Carbon Fiber)

Mold in 2 parts used to apply the CF skins (T300)

First 2 proto received so far for lay up validation (2 plies wrt 3 plies)

1 2 3

Bonding of 2 sub parts

Next 20 parts in production @ Composite Design…

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Prototype program 2010-2011 [3]

Complete cross beam (equipped with end parts in Peek) Cross beams processing (in Carbon Fiber) Cross beams processing (in Carbon Fiber) Re machining on CNC (use of jigs, clamps,…) ⇒ Cross beams cut to final shape Multi purpose jig ⇒ Assembly and Machining of end parts in peek

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Prototype program 2010-2011 [4]

Bonding and centering

• f different parts

Assembly jig Assembly jig Grooves

Jig made out of cast aluminum (called “G25”) Jig received this week @ DPNC

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Prototype program 2010-2011 [5]

Jig and cradles to provide precise positions, clamping for bonding

Assembly jig Assembly jig

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Prototype program 2010-2011 [6]

Z1200 Z600 Z0

Could also be used a stand for future mechanical load tests (beginning of 2011)

Centering parts (x3) for locking mechanism bonding Assembly jig Assembly jig

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Prototype program 2010-2011 [7]

Ready for future tests (2 carbon fiber structures foreseen early in 2011) C

• l

i n g p l a t e s … s e e n e x t Assembly jig Assembly jig

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Prototype program 2010-2011 [8]

Cooling plate in CC-2D (2800), as machined by the KEK workshop (as shown at the 2008 June review, by S. Terada) Cooling plate Cove

Ø2.5Pipe

Cross section

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Integration to the structure and FEA’s [1]

FEA’s on Super Module (stress and sagging / 3 loads: Vertical, 16° , horizontal)

Meshing

Sandwich of Silicon wafer + TPG

Different plies and orientation of M55J fiber have been studied for Back bone… the rest in QI lamina (T300). Total weight from FEA: 800 gr.

1G 1G 1G

3 load cases considered

1200mm

Z0 Z1200

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Integration to the structure and FEA’s [2]

FEA’s on Super Module (stress and sagging / 3 loads: Vertical, 16° , horizontal)

• f1: 57 hz

Eigenvalue 10 11 Horizontal 12 80 Vertical 11 77 16° Max Stress (Mpa) Deflection (micron) Load case

1G

Carbon fiber Layup (M55J) Module material assembly

Modal shape

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Integration to the structure and FEA’s [3]

FEA’ s Extrapolations to a longer SM …in case the Barrels will extend up to …??

1600mm 1600mm

Z0 BC’s inwards shifting (200mm)

Case 1: extension to 1600mm Case 2: extension to 1600mm + NEW BC’s

« Z200 »

1 G sagging / Vertical

« Z200 » Z0 Middle BC Uz (micron)= 166 ! Uz (micron) = 73

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Integration to the structure and FEA’s [4]

End Insertion using a removable backbone Backbone

The SM slides w/o stress into the structure (locking in 3 positions)

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Integration to the structure and FEA’s [5]

No Module shown (for clarity). Locking points over the length (Qty: 3)

Z0 Z600 Z1200

Reinforcing ring and single skin cylinder Sliding guides

Z0 Z600 Z1200

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Integration to the structure and FEA’s [6]

End view on a few SM, for cylinders 1 and 2…, … Cable bus to be optimized

16°

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Integration to the structure and FEA’s [7]

Overall sagging: 4x2 Interlinks clamped to the Outer cylinder 8 Hz (axis mode) Eigenvalue 127 1400! 2x2 48 300 3x2 30 203 4x2 Max Stress (Mpa) Deflection (micron) BC case

Boundary Condition (the way it’s clamped to the Outer Cylinder)

Nota: the margin of safety on the mass is 20% (due to SM overestimated). PIXEL is based on 300Kg (!) …to be reconsidered

Details on reinforcing rings… could be filled in with foam (better rigidity) CAD model

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Conclusions / Outlooks beyond 2010

The optimization work (thanks to CAD and confirmed by FEA’s) shows that the Super Module in term of X0 still have some potential to improve: 2,58% with proposed LS Competitive number with respect to stave concept In parallel to the “8 modules” project, we will build 2 full scale prototype in CFRP

• f the Super Module by the end of 2010-beginning of 2011.

Structural tests will be carried out on the prototypes along with thermo elastics tests (?)