J.H. ChrzanowskiMod Coil R&D Update1 Modular Coil R&D Keystone Activities April 30, 2003 James H. Chrzanowski

J.H. ChrzanowskiMod Coil R&D Update2 Keystone Trials- The Keystone winding trials have begun. Initial measurement of winding surface was performed using “Faro” measuring arm. Bench top tests were performed

J.H. ChrzanowskiMod Coil R&D Update3 FARO Arm Measurements Plot from Faro arm measurements Have not compared with original Pro-E model

J.H. ChrzanowskiMod Coil R&D Update4 Keystone Bench Top Tests Bench top tests were performed comparing the single copper conductor vs. 4-rope conductor Lengths of insulated [1 half lapped layer of dry glass only] copper rope specimens were wound onto a 3.5 inch diameter pipe

J.H. ChrzanowskiMod Coil R&D Update5 Width0.545 Height0.660 Prior to Winding B A D C After Winding Height Width A B CD Single Conductor- Results of Bench Top Tests

J.H. ChrzanowskiMod Coil R&D Update6 4-Rope Conductor- Results of Bench Top Tests A B C D Height Width Height0.670 Prior to Winding B A D C After Winding

J.H. ChrzanowskiMod Coil R&D Update7 4- Rope Conductor Position A B C D Position Width Height After Winding Prior to Winding

J.H. ChrzanowskiMod Coil R&D Update8 Keystone Trials - 4 Rope Conductor Extreme distortion and twisting of the individual copper ropes

J.H. ChrzanowskiMod Coil R&D Update9 Additional Issues Insulating the 4-rope conductor via the taping machine is extremely difficult Twisting and separation of the ropes causes inconsistent application of insulation The single conductor offers less of a challenge

J.H. ChrzanowskiMod Coil R&D Update10 Keystone Trials- Forward progress was needed Decision was made to use our remaining 20 feet of single conductor to gain some preliminary Keystone data Single copper conductor was hand insulated with glass and Kapton, positioned onto the winding form and clamped in place

J.H. ChrzanowskiMod Coil R&D Update11 Preliminary Keystone data One observation made is that varying the clamp pressure can result in a ~0.008" change in the measurement.

J.H. ChrzanowskiMod Coil R&D Update12 Keystone Fixture Locations

J.H. ChrzanowskiMod Coil R&D Update13 Preliminary Findings - Preliminary Keystone R&D activities have shown that the single conductor has many advantages over the 4-rope conductor. It was hoped that the 4-rope conductor would reduce keystoning. In fact the opposite is true. The conductors cannot slide to each other without causing extreme distortion. Using an automatic taping machine on the 4-rope conductor is a nightmare. Inconsistent layers plus loose conductors are all counterproductive

J.H. ChrzanowskiMod Coil R&D Update14 Conductor Recommendation Seriously consider returning to single conductor as baseline plan for modular coils perhaps 34 ga instead of 36 ga Procure additional single copper rope conductor for completing the Keystone tests (Carm Hjelm from New England wire will have a quote to me by tomorrow. He expects delivery by approx. June 6 th.) Use the 4-rope conductor for winding the demo(racetrack) coil – Hand insulate if necessary Use the 4-rope conductor for balance of specimens for CTD mechanical thermal tests. Prepare several single conductor specimens for comparison with 4- conductor test results Use single conductor for next major VPI of twisted tee