LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 16 May 2006 No 1 /22 LARP Phase II Secondary Collimator RC1 Collimator Test Program Revised 5/15/06

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 16 May 2006 No 2 /22 LARP Phase II Secondary Collimator RC1 Collimator Test Plan Near term –Jaw/Cooling Tube Joint Development –Single Jaw Thermal Tests Later this year…… –Design and fab hardware for Mechanical Prototype Tests

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 16 May 2006 No 3 /22 Jaw/Cooling Tube Joint Development Purpose: determine appropriate joint configuration & fabrication methods In process.. target completion date Square hollow magnet conductor for first test ~ 9 mm x 9 mm Copper jaw and mandrel Cu-Au braze After first braze, machine coil o.d. for correct fit to jaw i.d. After second braze, section assy to inspect coverage Round tubing with grooved (?) mandrel is next May 18 th Cooling Tube Jaw Center Mandrel ~100 mm ~70 mm dia ~100 mm dia

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 16 May 2006 No 4 /22 Jaw/Cooling Tube Joint Development –Cooling Tube cross-section Options Preferred method is round tubing in a ‘D’ shaped groove –Flattening of tube can be done by rolling with alcohol lubricant in “clean” environment –May require several groove shape attempts to obtain braze uniformity (will start with.5 mm flattening of tube) –Material should be available in Copper Alloy 101 OFE Class 2 ASTMF- 68 Square tubing in square groove requires a machining step prior to second braze –This may be a difficult machining operation without lubrication –Material availability may be a problem »Only certain od/id combinations are available »Chemical composition is a concern wrt (see above)

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 16 May 2006 No 5 /22 Jaw/Cooling Tube Joint Development –Determine Mandrel/Cooling Tube features and develop the winding process Select constant or varying pitch grooves (ANSYS) (Eric) Design dummy parts for round tube test (Steve) –Design tightening feature for center u-bend location –Determine if bend radius is adequate to prevent crushing »Perform tight radius bends in tube with/without cerrobend or other recommended material (to prevent crushing) Perform preliminary winding test(s) –Develop best winding techniques for manufacturing process –QA assembly prior to brazing with “ball test” of completed Mandrel assembly (80% diameter spherical bead)

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 16 May 2006 No 6 /22 Jaw/Mandrel/Cooling Tube R&D Plan Forward Square Tube is currently brazed to mandrel Machine od of coil to clean up winding deformation Machine id of Jaw to suit coil od Braze assembly together Machine into sections to inspect braze joint Square Cooling Tube Braze Test Document results with photos and writ-up of complete process Today

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 16 May 2006 No 7 /22 Jaw/Cooling Tube Joint Development Ready for brazing

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 16 May 2006 No 8 /22 Jaw/Cooling Tube Joint Development Glidcop Test Jaw showing “D” groove, entrance and exit ports for cooling tube Copper plating (.05mm thick) is required on outer surface prior to brazing on the OFE copper tubing Plating, winding, rolling and brazing techniques will be developed during this test

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 16 May 2006 No 9 /22 Single Jaw Thermal Test Hardware –Long lead items (2-6 weeks) 2x Heater controllers are on order… due mid June Ready to buy 4x 5kW electric resistance heaters (380 mm long) Ready to buy Glidcop material for 1 Jaw (2 Halves) Ready to buy Glidcop material for 1 Mandrel Ready to buy molybdenum mat’l for Shaft (2 Halves) (vendor stock) –Heater Mount Determine appropriate material Design Mount profile for reasonable heat flow into facet Mount sections are 25 mm long to minimize effect on Jaw stiffness Bore to be.05 mm dia oversize of actual heater size (15.88 mm dia) Attach to facet by brazing (hold in alignment with dummy heater) –Thermocouple attachments in Jaw Locations, depth, size, electrical isolation features in Glidcop Jaw

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 16 May 2006 No 10 /22 Single Jaw Thermal Test Hardware cont’d –Jaw Support( bearings and mount) RC1 Bearings Mount them on “V” blocks or? –Rigid mounting for capacitance sensors Locate at ends and center of Jaw

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 16 May 2006 No 11 /22 Single Jaw Thermal Test Hardware –Ready to buy the following from National Instruments: 1 each SCXI-1600 USB Data Acquisition and Control Module 1 each SCXI Slot Chassis U.S. 120 VAC 1 each SCXI Channel Isothermal Terminal Block 1 each SCXI-1374 Handle Kit for PXI each SCXI-1102C 32-Channel Amplifier, 10 kHz Bandwidth 11 each SCXI-1361 Rear Filler Panel Cost is about $4500 –Find a PC to use for the duration of the Experiment Probably available at no cost –Download LabView from SLAC website License is $700 Software is ???

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 16 May 2006 No 12 /22 Single Jaw Thermal Test Hardware Cooling Coil/Mandrel/Shaft Assembly

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 16 May 2006 No 13 /22 Cooling Coil/Mandrel/Shaft Assembly Section When inlet and outlet cooling tubes exit the shaft on the bearing axis each tube will twist on its own axis when the collimator is rotated

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 16 May 2006 No 14 /22 Single Jaw Thermal Test Hardware Cooling tube entrance and exit detail

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 16 May 2006 No 15 /22 Single Jaw Thermal Test Hardware End View of Cooling Coil wound on to Mandrel

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 16 May 2006 No 16 /22 Single Jaw Thermal Test Hardware Glidcop Al-15 Half Jaw Inner bore is tapered to facilitate assembly Glidcop cost is $7884 each

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 16 May 2006 No 17 /22 Single Jaw Thermal Test Hardware Jaw / Heater / Sheath Assembly cross section 38x 25 mm long Heater Mount 2x 5kW Heater Braze Mounts to Jaw facet

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 16 May 2006 No 18 /22 Single Jaw Test Thermocouple Locations Thermocouples are recessed into Jaw slightly below the surface Spaced along Heater length and equally spaced half way around Jaw circumference Should yield the Jaw heating profile predicted by the FE analysis 16 x Thermocouples 2 x 5kW Heaters 30 x Mount (brazed to Jaw)

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 16 May 2006 No 19 /22 Single Jaw Thermal Test Hardware DAC & Control Block Diagram PC with LabView Software Heater #1 Controller Heater #2 Controller Capacitec Signal Amplifier DAC & Signal Processor Jaw thermocouples Jaw deflection sensors Jaw Heater #1 Jaw Heater #2 Over Temperature Control

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 16 May 2006 No 20 /22 RC1 Mechanical Prototype Test Purpose: bench top testing of the jaw actuating mechanism in CERN orientations –Vacuum tank with easy access –CERN adjustment mechanism –SLAC cooling water feed-throughs and flexible connections –SLAC rotation mechanism –Simplistic control system for jaw aperture –Minimal instrumentation connections for position, temperature, etc. –RC2 will incorporate LHC-compliant interfaces –Heat loading may not be possible –Use CERN Phase I components as appropriate

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 16 May 2006 No 21 /22 RC1 Mechanical Prototype FY08, RC2 FY07 RC1 consists of jaws, tank & actuators - evaluated for horizontal (shown), vertical (90 o ) and skew (+/- 45 o ) orientations. Variant: use CERN vac tank, dummy jaws of correct weight

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 16 May 2006 No 22 /22 Development/Test Lab Itemavailability Chillerexisting Vacuum equip’tSLAC misc? Heater controllerselect/buy Gantryselect/buy Tools, tableselect/buy Instrumentationselect/buy Power/waterto be installed