NBourcey on behalf of MQXF collaboration team O utline MQXFSD0 structure assembly MQXFSD2 structure assembly MQXFSD3 specific tooling Connection box Conclusion February 2nd 2016 NBourcey ID: 790823
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Slide1
Slide2MQXFSShort Model Assembly and lessons learned at CERN
N.Bourcey
on behalf of MQXF collaboration team
Slide3OutlineMQXFSD0 structure assemblyMQXFSD2 structure assemblyMQXFSD3 specific toolingConnection boxConclusion
February 2nd 2016
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Slide4Assembly workflow & tooling listStep
Description
Tooling
1
Yoke and shell assembly
SQXF10: Yoke and shell
assy
tooling
SQXF20: Yoke and shell turning benchRotating deviceYoke and shell lifting tool2Coil pack assemblyGI manufacturing toolingSQXF30: GI assemblySQXF40: Coil rotating toolingSQXF50: Coil pack assy toolingCoil and coil pack lifting toolSQXF80: Lamination assembly3Coil pack / shell introducingSQXF60: Introducing bench4Longitudinal pre-loadingLongitudinal pre-loading tooling5Connection box assemblyCables bending toolsSplicing tool
February 2nd 2016
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Slide5MQXFSD0 assemblyFebruary 2nd 2016
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Slide6Yoke and shell assemblyFebruary 2nd 2016N.Bourcey
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Bladder pressure
Yoke key 1
Yoke key 2
Yoke key 3
Yoke key 4
550 bars
12.1mm12.2mm12.2mm12.2mmAssembly using 4 bladdersHigh pressure (around 550 bars)Difficult to insert the keys
Yoke lifting and rotating tool
Slide7GI manufacturingFebruary 2nd 2016N.Bourcey
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Kapton
forming at warm
(200degC over the night)
G11 foils glued on the collar assembly
→
difficult to keep in place
→ thickness not preciseDifferent plate width for coil GI or collar GI
Slide8GI assemblyFebruary 2nd 2016
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Kapton
glued on coil
Cut
K
apton
around pole grooveG11 and Kapton on collarsDummy coils ready for assembly
Slide9Coil pack assembly MQXFSD0February 2nd 2016N.Bourcey
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Assembly of the dummy coils with Fuji paper
Assembly of the collars. Bolting 10
N.m
Measurement of the gap in-between collars
Second assembly with full GI and defined pole keys
Load-pad
assembly. Bolting 20 N.mLoad-pad key difficult to insert in the collar assembly
Slide10Coil pack lifting toolFebruary 2nd 2016N.Bourcey
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Lifting of the coil pack with or without top master
Slide11Coil pack / shell introducing
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Fixed rail
Mobile rail
Horizontal reference plane
Alignment procedure:
Install Yoke and shell on reference supportsInsert rail in the yokeAlign front table (rail as reference)
Slide12Coil pack / shell introducingFebruary 2nd 2016
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Install master. The side master are bolted to the
loadpad
in the extremity.
Pull coil pack in the shell
Start bladder operation by the bottom to remove rails.
Perform bladder operation by quadrant. Maximum pressure 400 bars for 13.55mm keys (1400 microstrain in the shell)
Slide13End plate assembly and axial loadingFebruary 2nd 2016
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Axial loading 460 um/m
Slide14MQXFSD2 assemblyFebruary 2nd 2016
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Slide15From MQXFSD0 to MQXFSD2What as changed?In term of design3 shells instead of 2In term of assemblyNew yoke and shell assembly toolingCoil pack assembly bench ready
February 2nd 2016
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Slide16Yoke and shell assemblyFebruary 2nd 2016N.Bourcey
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Change cross for 8 bladders
Slide17Yoke and shell assemblyFebruary 2nd 2016N.Bourcey
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New cross beam for 8 bladders fail due to insufficient supporting of the bladders
Slide18Yoke and shell assemblyFebruary 2nd 2016N.Bourcey
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Bolting of the yoke assembly to the yoke via the shell cut
No pre-loading of the yoke in the shell
No yoke keys
Slide19Yoke and shell assemblyFebruary 2nd 2016N.Bourcey
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Geometrical control of the assembly shows good result
Courtesy
J.Ferradas
Slide20Coil pack assembly toolingFebruary 2nd 2016
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Initial design:
Assembly of the collars – bolting
Assembly of the load-pads – bolting
Alignment fixture to allow insertion of the load-pad key in the collars
SQXF50
Slide21MQXFSD0 coil pack disassemblyFebruary 2nd 2016N.Bourcey
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The commissioning of the bench has ben done during the disassembly of MQXFSD0
Several design problem discovered:
Alignment fixture is not working properly
Load-pads have to be aligned by master surface
Slide22MQXFSD2 coil pack assemblyFebruary 2nd 2016N.Bourcey
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The assembly of the coil pack for D2 was made in order to validate the concept of the laminated structure D3 and the assembly procedure.
→ assembly of load-pads and collar in one go
→
no screw on the collar
→
bolting of load-pads each 350mm
Courtesy J.Ferradas
Slide23MQXFSD3 assemblyFebruary 2nd 2016N.Bourcey
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Slide24MQXFSD3 exploded viewFebruary 2nd 2016N.Bourcey
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Pads will be assembled using
50 and 25 mm thick SS pieces at magnet extremities
5.8 mm thick “
M
agnetil
” laminations (LHC type iron used for MB)
25 mm thick Armco pieces between thin laminationsAluminum collars geometry will not be changed except for the inner radius still TBDSlide from JC Perez presentation (July 2015)
Slide25MQXFD2 vs. MQXFSD3February 2nd 2016N.Bourcey
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Slide26MQXFSD3 aluminum collarsFebruary 2nd 2016N.Bourcey
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Aluminum collars will be machined and delivered as single part
Collars will be assembled on top of the pad, aligned using bushes and bolted with a full length SS rods
On stock
Slide from JC Perez presentation (July 2015)
Slide27MQXFSD3 load-padsFebruary 2nd 2016N.Bourcey
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The central part of load-pads packs will be assembled using a SS tube (tack welded at the extremities)
50 mm SS pieces at the end of the load-pad will be assembled using short bushes
On stock
Slide from JC Perez presentation (July 2015)
Slide28MQXFSD3 laminated yokesFebruary 2nd 2016N.Bourcey
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Same configuration as per load-pad assembly (pre-assembly of 3 lamination packs and insert 50 mm plates for bolting)
On stock
Slide from JC Perez presentation (July 2015)
Slide29MQXFSD3 lamination pack assemblyFebruary 2nd 2016N.Bourcey
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SQXF80
Validation of the assembly procedure
Slide30MQXFSD3 lamination pack assemblyFebruary 2nd 2016N.Bourcey
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Courtesy
A.Carlon
Zurita
Slide31Yoke and shell assemblyFebruary 2nd 2016N.Bourcey
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Design v2
Design v3 (ready for MQXFSD3)
Slide32MQXFSD3 coil-pack assemblyFebruary 2nd 2016N.Bourcey
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Bolting of the load-pads for coil pack assembly will be performed using screws spaced by ≈350 mm
Assembly procedure tested with MQXFSD2
Assembly with dummy coils foresee in March
Slide33MQXFSD3 coil-pack assemblyFebruary 2nd 2016N.Bourcey
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New load-pads supports
No alignment fixture
Assembly of load-pads and collars together
Slide34Coil rotating tooling & coil liftingFebruary 2nd 2016
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SQXF40
2 coils lifting tool
Not yet available for the assembly of MQXFSD0
Validated for assembly of MQXFS2 together with the associated lifting tools
Slide35Connection box – 1st conceptFebruary 2nd 2016N.Bourcey
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A mock-up was built to perform the development of the connection box.
(bending tests, tooling development…)
→
forming
difficult
(distance between radius and twist too short)→ contact between cables
Slide36Connection box – final designFebruary 2nd 2016N.Bourcey
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→
Larger radius (25mm)
→
No more contact between cables
→ Tooling under procurement
→ To be tested on the mock-up
Slide37Interconnection schemeFebruary 2nd 2016N.Bourcey
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From
E.Ravaioli
Slide38ConclusionMQXFSD0 and D2 allow us to improve all the assembly tooling and procedure.Final tooling is nearly ready for the assembly of MQXFSD3.No major assembly issue is expected for the assembly of the first magnet.
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Slide39February 2nd 2016N.Bourcey39
Thank you for your attention!
Special thanks to all the contributors to this presentation and the assembly team for the good job!