MQXFB design, assembly plans & tooling at CERN J.C Perez On behalf of MQXF collaboration team MQXF Workshop on Structure, Alignment and Electrical QA CERN 2-4 February 2016

OUTLINE  MQXFB magnet design  MQXFB assembly plans and tooling at CERN  Conclusions February 2-4th 2016 J.C. Perez MQXF Workshop at CERN3 Special thanks to Bruno Favrat for his contribution to this presentation !

MQXFB magnet design February 2-4th 2016 J.C. Perez MQXF Workshop at CERN4 ≈7.5 meters long coils 50 mm thick aluminum collars Coil angular positioning w.r.t collars using radiation resistant G10 alignment keys Pads assembly : combining 5.8 mm and 28 mm pieces ≈ 3.8 m long masters & bladders Jokes assembly : using 5.8 mm and 46 mm thick pieces 10 long and 2 short aluminum shells ≈ 8.5 long rods for longitudinal loading ≈ 10 meters long ½ SS shells to be welded

¼ Yoke packs preparation February 2-4th 2016 J.C. Perez MQXF Workshop at CERN5 5 modules of yoke + shells per magnet pre-assembled using bladders and yoke keys ¼ yokes assembly operation will be performed on horizontal position using temporary tie-rods 2 & 3 shells configuration to be assembled 50 mm thick plates are required at shells junctions to bolt the supporting blocks for backing strip welding (strips tack- welded to the blocks) 3 Shells configuration 1 short & 2 long 1708 mm 2 Shells configuration 1368 mm

Yoke and Shell assembly February 2-4th 2016 J.C. Perez MQXF Workshop at CERN6 Assembly performed in vertical position and then pivoted Bolting yokes against the shell throw shell windows may be considered as an alternative solution for bladders operation (see Nicola’s presentation) Smaller yoke-keys will be used for safety Temporary rods will be removed after yoke-keys insertion Assembly procedure and comparative geometrical measurements to be validated during MQXFSD3 mechanical structure assembly (Feb-2016)

Yoke and Shell modules assembly February 2-4th 2016 J.C. Perez MQXF Workshop at CERN7 Each individual yoke pack will be measured during MQXFSD3 and prototypes assembly phase 2 mm gap to be guaranteed in between 2 adjacent yoke/shell sub-assembly (yoke longer by 1 mm at each extremity by design) Overall magnet length to be adapted? Can be done by machining the 2 SS end-plates

Yoke & Shell modules assembly table February 2-4th 2016 J.C. Perez MQXF Workshop at CERN8 The horizontal alignment plane will be defined by the top surface of the pieces holding the 2 vertical ¼ yokes at each shell extremity 6 alignment fixtures equipped with cylindrical pins will ensure the lateral position of the yoke/shell sub-assemblies and guarantee the full assembly straightness over ≈7.5 m Horizontal reference plane Transversal alignment

Yoke & Shell modules assembly(1/4) February 2-4th 2016 J.C. Perez MQXF Workshop at CERN9 3 shells module will be placed on its support feet and blocked in longitudinal direction The next module will be placed on top of its corresponding feet with a distance between 2 adjacent shells of ≈10mm

Yoke & Shell modules assembly (2/4) February 2-4th 2016 J.C. Perez MQXF Workshop at CERN10 10 mm Contact See next slide

Yoke & Shell modules (3/4) February 2-4th 2016 J.C. Perez MQXF Workshop at CERN11 Hydraulic cylinders (if required) and intermediate tie-rods will be used to pull and temporary clamp 2 modules together The contact between 2 sub-assemblies will be located on the faces of the thick extremity lamination plates Temporary tie-rods will be removed after compressing the modules No alignment pins will be used in between 2 modules (final magnet alignment provided by bladders operation when loading the coil- pack: to be confirmed during first prototype assembly)

Yoke & Shell modules (4/4) February 2-4th 2016 J.C. Perez MQXF Workshop at CERN12 The same sequence will be repeated to assemble the 4 remaining modules using tie-rods adapted to the required length

Load pads and aluminum collars assembly February 2-4th 2016 J.C. Perez MQXF Workshop at CERN13 Stainless steel tube tack welded for thin laminations assembly The central part of load-pad packs will be assembled on top of a reference table using a SS tube (tack welded at the extremities) 50 mm SS pieces will be then assembled using 50 mm bushes Stainless steel rods will be used for longitudinal compression The aluminum collars will be assembled on top of the full length ¼ pad assembly using bushes Top part and pad indentation will be used as assembly reference plans for ¼ collar packs Stainless steel rods will compress the collar assembly

7.5 meters Coils assembly February 2-4th 2016 J.C. Perez MQXF Workshop at CERN14 4coils ≈7.5 meters long to be assembled (How to support them over the full length?)

Coil-pack assembly (1/2) February 2-4th 2016 J.C. Perez MQXF Workshop at CERN15 Assembly method as for MQXFS Upper ¼ pad & collars preparation

Coil-pack assembly (2/2) February 2-4th 2016 J.C. Perez MQXF Workshop at CERN16 Aluminum collars will not be bolted Bolting of the load-pads for coil pack assembly will be performed using screws spaced by ≈350 mm The new assembly procedure has been tested at CERN (using MQXFSD0 first structure: thick laminations ) during MQXFSD2 assembly (3 shells configuration). The same procedure will be applied on MQXFD3 mechanical structure assembly (new laminated structure using a 3 aluminum shell configuration: see Nicola’s talk)

Masters assembly February 2-4th 2016 J.C. Perez MQXF Workshop at CERN17 The masters will be bolted to the pivoting supports for assembly operation Temporary removable clamps will be placed around the coil-pack and masters to guarantee their correct positioning during insertion operation

Coil-pack insertion February 2-4th 2016 J.C. Perez MQXF Workshop at CERN18 The same insertion table concept used for MQXFS assembly will be scaled-up for MQXFB coil-pack insertion

Coil-pack insertion February 2-4th 2016 J.C. Perez MQXF Workshop at CERN19

Longitudinal compression and connection box February 2-4th 2016 J.C. Perez MQXF Workshop at CERN20 The connection box will be mounted after shell welding operation End-plate assembly and axial loading using the system validated on MQXFS

Conclusions MQXFS assembly procedure has been defined and is being tested during MQXFS model program The assembly procedure will be extrapolated for MQXFB construction and validated on the first prototype to be built at CERN from February 2016 on Most of the existing tooling can be scaled-up from models to 8 m long magnet Structure components detailed design to be completed by summer 2016 First MQXFB prototype (mirror configuration) assembly scheduled for Q Handling and assembly tooling to be designed and manufactured No show-stopper identified so far February 2-4th 2016 J.C. Perez MQXF Workshop at CERN21

February 2-4th 2016 J.C. Perez MQXF Workshop at CERN22 The HiLumi LHC Design Study is included in the High Luminosity LHC project and is partly funded by the European Commission within the Framework Programme 7 Capacities Specific Programme, Grant Agreement Thank you for your attention