IBL Mock Up - PowerPoint Presentation

Slide1

IBL Mock Up

IBL Mock Up MANUFACTURING2011/04/29François-Xavier NUIRYMaxence CURDYAndrea CATINACCIO

CERN PH/DT/PO

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Summary

IBL Mock Up V01, aluminium stavesBeam pipe manufacturingMock up assembly procedureThermal set up

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IBL Mock Up V01 Staves Fabrication Process

What we had :

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IBL Mock Up V01 Staves Fabrication Process

What we have :

What we need if we want to respect geometrical envelops :

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IBL Mock Up V01

Staves Fabrication Process

1- Setting the cutter head at 17⁰

2- Machining the 14 aluminium parts to lower the angle

[22 ⁰

17

⁰

]

-Machining the parts to reduce

the length [780 mm

748 mm]

3-

Drill 2 holes with spacing of 736 mm

4- And finally machining 2 slots

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3

2

4

x14

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IBL Mock Up V01 Ring Tool

Manufacture of Ring Tool

To hold the ring in position and be able to keep the spacing of 736 mm, we’ve designed ​​a Ring Tool with pins and a clamping system.

Clamping System

Pins

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IBL Mock Up V01

Ring Tool

A

A

B

A

B

To keep the spacing between Rings during the assembly, the holes are perfectly located.

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IBL Mock Up V01

Ring Rework

Rings are made ​​in Stereolithography (SLAC)

1 - To machine holes for the screws, the ring is positioned on the Ring Tool : alignment, drilling Ф2mm and tapping M2.5

2- We’ve kept the same tool to drill the ring supports holes: alignment, drilling Ф1.2 and boring Ф1.5H7

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2

x2

Ring support

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IBL Mock Up V01

Parts Assembly

1- Staves are attached to the ring with screws M2.52- Ring supports are assembled to the ring through pins Ф1.5

3- Thanks to ring supports, the IBL prototype slides in the IST. (The IST inner surface roughness allows an easy insertion, without grease)

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3

2

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Mock up available for integration and thermal test!Slide10

Beam pipe manufacturingFunctional specs

Main objectives:Getting a thermally active beam pipe, in order to simulate back out conditionsAble to heat up to 250˚CMaterials specified in the TDRAutomatic temperature control, with systems anti over heat

Be able to perform some integration testsInternal envelop = 45mm

External envelop = 55.7mmSlide11

Beam pipe manufacturingMaterials used

Part

Material

CommentsTube

[Beryllium]



Aluminium

6061 T6

(

ρ

=2.713, K=167 W/

m.K

)

ID=44.68mm OD=46.78mm l=2.440m

Supplier = Online metal [USA]

Physical properties closed to beryllium

(

ρ

=1.85, K=216 W/

m.K

)

Heaters

[

Kapton

heaters

]



Watlow

Silicon rubber heaters, 0.6mm thickness

Cheaper than

kapton

heaters, but a bit more thick (0.6 instead of 0.2mm)

Polyimide film

Kaneka polyimide film,

2 layers (2*6

μ

m)

The original one used in current

beam pipe

Aerogel

ASPEN

aerogel

7mm thickness

Re-machined to lower

the thickness

~4 mm

Polyimide film

Kaneka polyimide film,

2 layers(2*6

μ

m)

The original one used in current

beam pipe

Glue

Epotecny

P101

Polyimide resin,

resist up to 576 ˚C

125 g = 436 Euros !

Thickness not controlled

Aluminium foil

Standard

aluminium foil

1 layer = 5

μ

mSlide12

Beam pipe manufacturing

Fabrication process1- Machining the alu pipe to lower the thickness [1.61.05mm]2- Mounting the pipe on the rolling support3- Fix thermocouples4- Mounting heaters (rolled around the tube)

5- Wrapping 2 layers of polyimide tape and cure it (1 hour at 200˚C)

6- Wrapping 1 layer of aerogel7- Wrapping 2 layers of polyimide tape and cure it (1 hour at 200˚C)8- Gluing the aluminium foil and cure it (1 hour at 200˚C)

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2

5 and 7

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6 : no picture du to the huge amount of dust in the room

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Polyester shrinking tape before curing (removed after curing)

8: still not done, because we keep the possibility to check the heat dissipation with the Infra-red camera

Auto-electric rack:

Automatic temperature controlSlide13

Beam pipe manufacturingResults

What we have

What we tried to get

A full thermo active beam pipe, able to heat up to 200˚C.

We can heat up to 230˚C for few minutes.We did not heat up to 250˚C. This could damage heaters cables.

An geometrical envelop globally controlled

(Average outer diameter ~54.6 mm,

without aluminium foil)

This variation is mainly due to 2 reasons:

-Non regularity of

aerogel

-presence of heater leads

It is quite hard to wrap

the

aerogel

on the pipe: It generates a lot of dust and controlling its thickness is not easy

 we should order

aerogel

with the right thickness (3mm) for futures beam pipes

55.2

54mmSlide14

Beam pipe manufacturing

Thermography

Thermography

during first cure

(just a qualitative study)

Global view during the heating step 50˚C / hour

Impact of the thermocouple cable on the heat dissipation

Heat dissipation at extremities: to be taken into account in the curing

One heater receiving power during the heating step (normal behaviour)

Thermography

After having equipped the pipe with

aerogel

and polyimide tape.

(200˚C fixed on the aluminium tube)

Globally, we can say that we reach 86 ˚C on the outer surface of the polyimide tape, when the alum pipe temperature is set to 200 ˚C

Extremities are now well heated thanks to the addition of heating jackets around the pipe

This picture represent the length of the IBL. We can check that we globally have a homogeneous heat dissipation

Some non regularities in heat dissipation come from the silicon heaters leads (thermally more conductive)Slide15

Mock up assembly procedure

15Getting real staves for the IBL mock Up Goal: Integration tests + thermal tests + Flex fixation test

K13C Omega [0 90 0]

K13C Face plate [0] K9 Allcomp

foam Titanium pipes 2mm ID

Dummy silicon sensors, able to heat up to 100 W on 1 staveSlide16

Mock up assembly procedure

16Getting real staves for the IBL mock Up Goal: Integration tests + thermal tests + Flex fixation test

1. We glue the foam on the pipe

Foam + pipe assemblySlide17

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2. We glue the first assembly with Omega + EOS

Calibration tool

Mock up assembly procedureSlide18

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3. We machine the stave to get the right dimensionsMock up assembly procedure

We put the assembly in the female vacuum tool.

Stave assembly without face plate.

Female vacuum tool.

Extra foam and omega are to be cut by the diamond saw, in the Female mould.Slide19

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3. We glue the face plate on the foamMock up assembly procedure

Glue calibrator.

Stave assembly without face plate.

Face plateSlide20

Thermal set up

Aluminium frame nearly ended20

Black pipe = IST

White pipe = Beam pipe

Longitudinal and radial adjustment possible

 Keep the co-

axiality

between IST and beam pipe