ILC Rotating Target - Active Sliding Contact Cooling Wei Gai, Manoel Conde, Wanming Liu, Scott Doran, Vic Guarino, George Fenske (ES), Robert Erck (ES), Allen Zhao, Charles Whiteford, Frank Skrzecz

2 Active Sliding Contact Cooling Overview Deliverables - Summary Phase One - Drive System and Test Wheel Phase Two - Contact Cooling and Heating Systems Phase Three - Operation In Vacuum Internal Division of Effort Focus Today’s meeting is to discuss the overall plan to implement Active Sliding Contact Cooling to the ILC Rotating Target and how the plan meets expectations. Even though several design details are shown to communicate that we understand how to implement this cooling method, these details should be considered internal work in progress. June 4, 2015

3 Overview 1.Rotating 1M dia Target Wheel at 2k rpm (100 m/s) while extracting ~10kW by using active sliding contact cooling. 2.Target wheel is driven by a magnetically coupled drive motor which separates the motor from the vacuum. 3.Stability of wheel controlled by heavy duty machine spindle. 4.Temperature of wheel controlled by 4X Active Sliding Contact Cooling Pads. 5.Cooling Pad’s temperature controlled by water/coolant. 6.Heat applied to wheel using UHV radiant filament heaters. 7.Diagnostic feedback: RPM, Temp and Pressure of Cooling Pads, Temp of Target Wheel, Vibration, etc. 8.All material UHV compatible. All design parameters verified by our MathCad program Active Sliding Contact Cooling Full Size Target Wheel Ready for Operations in Vacuum

4 Phase One Magnetic coupled motor modified for vacuum. Procure spindle and bearings. Machined/balance full size wheel. Specify materials for contact area. Engineering and procurement of Phase Two. Deliverables - Summary Phase Two Implement Contact Materials. Install Active Sliding Contact Cooling and Heating systems. Engineering and procurement of Phase Three. Phase Three All systems working together in vacuum. Focus We will focus on each phase of deliverables as a building block toward the ultimate goal of a fully functional rotating target for the ILC. The phased approach allows for flexibility to improve the systems as we move forward and provides a realistic expectation of results. Our ability to complete this project in a given time frame is commensurate with the level of funding. Active Sliding Contact Cooling

5 Deliverables - Phase One - Drive System and Test Wheel Focus Phase One will be focused on the overall drive system, controls, and contact area material spec. What We Have Done: Procured a magnetically coupled motor that will be modified for use in vacuum. Worked with a vendor to develop a heavy duty block spindle for use in vacuum. Started the collaboration with Tribology to specify contact material. To Do: Engineer and procure a full size test target wheel, bearings, couplings, and supports. Align, assemble, and test the drive system. Tribology to make recommendations for the contact area material for use on target wheel and cooling pads. Build a safety cage. Active Sliding Contact Cooling

6 Deliverables - Phase One - Drive System and Test Wheel Magnatex - Magnadrive MP221 Motor, Modified for Vacuum One-Piece Base Shown for Clarity One Meter Diameter Two Inch Thick Aluminum Target Wheel Dynomax - High Speed, Heavy Duty Machine Spindle All Vacuum Compatible Components Coupling Contact Cooling Area on Wheel and Cooling Pads Material as Specified by Tribology Group Downstream Bearing and Frame Active Sliding Contact Cooling

7 Focus Phase Two will be focused on the contact material, cooling systems, and system controls. What We Have Done: Verified operational parameters (hp of motor, size of wheel, materials, coefficient of friction of contact area, size and temp of contact area, etc.). using our MathCad program. Specified vacuum compatible vendor products and materials for both systems. To Do: Apply material to the contact areas. Engineer, procure, and install cooling and heating systems and their controls. Test predictability of wear on wheel and pads. Decide what type of vacuum chamber we need (functional chamber, final deliverable, etc.). Engineer/specify and procure vacuum chamber. Deliverables - Phase Two - Cooling and Heating Systems Active Sliding Contact Cooling

8 Deliverables - Phase Two - Cooling System Details Controlled by Precision Linear Positioner Actuates a Load Cell (for pressure feedback) and Carriage that Rides on Four Linear Bearings Carriage Holds Active Cooling Pad Assembly Temp Monitored by Thermocouples Active Contact Cooling Pads are Spring Loaded and Ride on Large Shoulder Bolts that Slide Through Linear Bearings for Non-Binding Precise Motion Cooling Pads Temperature Controlled by Water/Coolant Contact Area Active Sliding Contact Cooling

9 Deliverables - Phase Two - Heating System Details Heating System - 4X Arrays of Alumina Housed UHV Filament Heaters Placed Outboard of the Cooling Pads to Simulate Heating along the Outer Diameter of the Target Wheel. Temperature of the Wheel Monitored by Infrared Active Sliding Contact Cooling

10 Focus Phase Three will be focused on all systems operating together in vacuum. What We Have Done: Specified vacuum compatible products and materials. To Do: Implement Phase One and Two Clean all parts for vacuum service. Re-install in vacuum chamber. Conduct long term test in vacuum. Deliverables - Phase Three - Operation In Vacuum Active Sliding Contact Cooling

11 Deliverables - Phase Three - Operation In Vacuum Once we have implemented Phase One and Two we will verify long term operations in vacuum. Active Sliding Contact Cooling

12 Deliverables - Phase Three - Operation In Vacuum Conceptual Functional Test Vacuum Chamber Shown for Clarity Active Sliding Contact Cooling