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MQXFS Short Model Assembly and lessons learned at CERN MQXFS Short Model Assembly and lessons learned at CERN

MQXFS Short Model Assembly and lessons learned at CERN - PowerPoint Presentation

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MQXFS Short Model Assembly and lessons learned at CERN - PPT Presentation

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

bourcey 2nd 2016n assembly 2nd bourcey assembly 2016n yoke pack coil shell assemblyfebruary load 2016 mqxfsd3 pads bolting collars

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Slide1

Slide2

MQXFSShort Model Assembly and lessons learned at CERN

N.Bourcey

on behalf of MQXF collaboration team

Slide3

OutlineMQXFSD0 structure assemblyMQXFSD2 structure assemblyMQXFSD3 specific toolingConnection boxConclusion

February 2nd 2016

N.Bourcey

3

Slide4

Assembly 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

N.Bourcey

4

Slide5

MQXFSD0 assemblyFebruary 2nd 2016

N.Bourcey

5

Slide6

Yoke and shell assemblyFebruary 2nd 2016N.Bourcey

6

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

Slide7

GI manufacturingFebruary 2nd 2016N.Bourcey

7

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

Slide8

GI assemblyFebruary 2nd 2016

N.Bourcey

8

Kapton

glued on coil

Cut

K

apton

around pole grooveG11 and Kapton on collarsDummy coils ready for assembly

Slide9

Coil pack assembly MQXFSD0February 2nd 2016N.Bourcey

9

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

Slide10

Coil pack lifting toolFebruary 2nd 2016N.Bourcey

10

Lifting of the coil pack with or without top master

Slide11

Coil pack / shell introducing

February 2nd 2016

N.Bourcey

11

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)

Slide12

Coil pack / shell introducingFebruary 2nd 2016

N.Bourcey

12

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)

Slide13

End plate assembly and axial loadingFebruary 2nd 2016

N.Bourcey

13

Axial loading 460 um/m

Slide14

MQXFSD2 assemblyFebruary 2nd 2016

N.Bourcey

14

Slide15

From 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

N.Bourcey

15

Slide16

Yoke and shell assemblyFebruary 2nd 2016N.Bourcey

16

Change cross for 8 bladders

Slide17

Yoke and shell assemblyFebruary 2nd 2016N.Bourcey

17

New cross beam for 8 bladders fail due to insufficient supporting of the bladders

Slide18

Yoke and shell assemblyFebruary 2nd 2016N.Bourcey

18

Bolting of the yoke assembly to the yoke via the shell cut

No pre-loading of the yoke in the shell

No yoke keys

Slide19

Yoke and shell assemblyFebruary 2nd 2016N.Bourcey

19

Geometrical control of the assembly shows good result

Courtesy

J.Ferradas

Slide20

Coil pack assembly toolingFebruary 2nd 2016

N.Bourcey

20

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

Slide21

MQXFSD0 coil pack disassemblyFebruary 2nd 2016N.Bourcey

21

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

Slide22

MQXFSD2 coil pack assemblyFebruary 2nd 2016N.Bourcey

22

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

Slide23

MQXFSD3 assemblyFebruary 2nd 2016N.Bourcey

23

Slide24

MQXFSD3 exploded viewFebruary 2nd 2016N.Bourcey

24

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)

Slide25

MQXFD2 vs. MQXFSD3February 2nd 2016N.Bourcey

25

Slide26

MQXFSD3 aluminum collarsFebruary 2nd 2016N.Bourcey

26

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)

Slide27

MQXFSD3 load-padsFebruary 2nd 2016N.Bourcey

27

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)

Slide28

MQXFSD3 laminated yokesFebruary 2nd 2016N.Bourcey

28

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)

Slide29

MQXFSD3 lamination pack assemblyFebruary 2nd 2016N.Bourcey

29

SQXF80

Validation of the assembly procedure

Slide30

MQXFSD3 lamination pack assemblyFebruary 2nd 2016N.Bourcey

30

Courtesy

A.Carlon

Zurita

Slide31

Yoke and shell assemblyFebruary 2nd 2016N.Bourcey

31

Design v2

Design v3 (ready for MQXFSD3)

Slide32

MQXFSD3 coil-pack assemblyFebruary 2nd 2016N.Bourcey

32

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

Slide33

MQXFSD3 coil-pack assemblyFebruary 2nd 2016N.Bourcey

33

New load-pads supports

No alignment fixture

Assembly of load-pads and collars together

Slide34

Coil rotating tooling & coil liftingFebruary 2nd 2016

N.Bourcey

34

SQXF40

2 coils lifting tool

Not yet available for the assembly of MQXFSD0

Validated for assembly of MQXFS2 together with the associated lifting tools

Slide35

Connection box – 1st conceptFebruary 2nd 2016N.Bourcey

35

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

Slide36

Connection box – final designFebruary 2nd 2016N.Bourcey

36

Larger radius (25mm)

No more contact between cables

→ Tooling under procurement

→ To be tested on the mock-up

Slide37

Interconnection schemeFebruary 2nd 2016N.Bourcey

37

From

E.Ravaioli

Slide38

ConclusionMQXFSD0 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.

February 2nd 2016

N.Bourcey

38

Slide39

February 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!