1. HL-LHC IR Corrector Magnets Conceptual Design & Construction Activity
Giovanni Volpini
on behalf of the LASA team
CERN, 1 July 2014

2. Giovanni Volpini CERN, 15 May 2014
linguine (supplier D, #7)
bucatini (supplier B, #9)
spaghetti (supplier D, #12)
spaghettoni (supplier D, #412)
maccheroncini
alla chitarra (supplier D, #13)
do not call them
just spaghetti…
Giovanni Volpini CERN, 15 May 2014

3. Corrector Magnet Summary Table I
General
SC wire
Name
Order
No of magnets for series
No of spare magnets
Aperture
Int strenght at radius = 50 mm
Iron outer radius
Loadline margin
4.2K 5T
Bare wire diameter
Cu/non Cu
Jc NbTi current density
Wire insulated diiameter mm
T·m A -
A/mm²
MCQSX 2 4
150
1.00
230
60%
350
0.7
2.3
3001.2
0.84
MCSX 3 1
0.06
160
179
0.5
3008.4
0.64
MCSSX
MCOX
0.04
MCOSX
MCDX 5
0.03
MCDSX
MCTX 6
0.086
MCTSX
0.017 36 12 48
Giovanni Volpini CERN, 1 July 2014

4. Corrector Magnet Summary Table II
General
Operational Values
Name
Order
Aturns
Number of turn: design value
Iop
Coil Peak Iop
3D magnetic length
(Iper)gradient
Overall current density
Overall current density: official value
Stored energy
Stored energy per unit length
Differential Iop
Linear 0 A - A T m
T/m^(n-1)
A/mm² kJ
kJ/m H
MCQSX 2
57,674
320
182.0
2.97
0.807 25
303.3
303
24.57
30.44
1.247
1.608
MCSX 3
28,193
214
131.6
2.33
0.111 11
353.0
350
1.28
11.61
0.118
0.179
MCSSX
MCOX 4
41,396
344
120.4
2.41
0.087
3,688
313.7
1.41
16.30
0.152
0.391
MCOSX
MCDX 5
35,672
256
139.1
2.34
0.095
50,623
359.7
360
1.39
14.69
0.107
0.301
MCDSX
MCTX 6
25,497
154
166.8
2.04
0.430
640,141
259.4
4.35
10.11
0.229
0.600
MCTSX
26,984
172
156.9
2.01
0.089
612,604
283.6
0.92
10.40
0.052
0.149
Giovanni Volpini CERN, 1 July 2014

5. Differential Inductance, a6
«zero-current» inductance, from linear-iron case, L = 149 mH
Ld(I) = 1/I dU/dI = ns2 / At dU/d At
Inductance [H]
Operating point
Ld = 52 mH
263/III
Giovanni Volpini CERN, 1 July 2014
Ampere·turns [At]

6. Corrector Magnet Summary Table III
General
Geometry details
Name
Order
Aturns
Coil cross section nominal
overall wire length for 1 coil
Max voltage rating to ground
External magnet diameter (iron yoke OD)
Weight: CS value
Coil Physical length
Yoke length
Overall iron length
Mechanical length end plate to e.p.
mm² m V mm kg
MCQSX 2
57,674
192
604.5
300
460
1000
840.8
800.8
871.5
890.5
MCSX 3
28,193
79.8
79.4
320 80
123.4
94.2
164.9
183.9
MCSSX
MCOX 4
41,396
132
88.1 70
98.7
70.7
141.3
160.4
MCOSX
MCDX 5
35,672 99
67.0 75
107.4
82.4
153.1
172.2
MCDSX
MCTX 6
25,497
144.1
250
449.0
424.0
494.6
513.7
MCTSX
26,984
41.5
101.5
76.5
147.2
166.3
Giovanni Volpini CERN, 1 July 2014

7. Corrector Magnet Summary Table IV
General
Protection
Forces
Wire needed
Name
Order
Dump Resistor
τ = L/R
Safety factor (current ratio)
"MIITs" exponential discharge
Wire MIITs
Discharge/Wire
Force: x component
Force: y component
Force: z component
Specific force: x-component
Specific force: y-component
Specific force: x-component from 2D model
Specific force: y-component from 2D model
Total wire required D0.7
Total wire required D0.5 Ω s -
A²·s N
N/m m
MCQSX 2
1.648
0.976
110%
19,549
19,473
100.4%
41,538
47,777
4,038
51,472
59,203
52,113
58,025
14,508
MCSX 3
2.279
0.078
821
5,069
16.2%
2,915
1,497
630
26,343
13,529
2,383
MCSSX
MCOX 4
2.492
0.157
1,376
27.1%
2,504
2,018
912
28,866
23,260
3,523
MCOSX
MCDX 5
2.157
0.139
1,632
32.2%
2,184
1,839
602
23,038
19,399
3,350
MCDSX
MCTX 6
1.799
0.334
5,612
110.7%
6,879
4,485
296
16,000
10,432
10,377
MCTSX
1.838
0.081
1,309
25.8%
1,386
1,125
330
15,608
12,668
2,986
Total for series + spares: kg
procured for prototypes: 38 kg
Giovanni Volpini CERN, 1 July 2014

8. LHC vs. HL-LHC corrector magnet
comparison chart
LHC
HL-LHC
Order
Type
Aperture
Stored energy
Operating Current mm
[J]
[A]
[mm]
[kJ] 2 S
MQSX 70
2,116
550
150
24.57
182 3 N
MCSTX 39
100
1.28
132
MCSOX 6 50 4 16
1.41
120 22 5
1.39
139 94 80
4.35
167
0.92
163
187/II
Giovanni Volpini CERN, 1 July 2014

9. Giovanni Volpini, CERN 19 June 2014
Quadrupole
891
460
yoke
coil
bore
Giovanni Volpini, CERN 19 June 2014

10. Iron yoke total length 800 mm
HX hole r = 185 mm
round bore flux return plate
Symmetric
flux return plate

11. Giovanni Volpini, CERN 19 June 2014
Design
Sextupole preliminary design
320
Yoke laminations machined by laser cut
followed by EDM (final accuracy 1/100 mm) on the relevant surfaces: poles, coil slots, alignment slots.
5.8 mm thick iron laminations
123
Giovanni Volpini, CERN 19 June 2014

12. winding and insulation
Winding machine:
-Commercial winding machine
-Home-developed braking system, controlling the wire tensioning between 1 and 20 kg ;
Insulation scheme:
-wire w/ S2 glass 0.14 mm thick (on dia)
-ground insulation applied after removing the coil from the winding tool w/ two crossed, 50% overlapped, 0.13 mm thick S-2 glass tape (total 0.52 mm)
Giovanni Volpini CERN, 1 July 2014

13. Giovanni Volpini CERN, 1 July 2014
Impregnation mould
Giovanni Volpini CERN, 1 July 2014

14. Giovanni Volpini CERN, 1 July 2014
Oven & impregnation
Temperature monitored with a PT100 on the mould, in agreement within +/- 1°C wrt the set temperature (in stationary conditions)
CTD-101K resin
Giovanni Volpini CERN, 1 July 2014

15. Giovanni Volpini CERN, 1 July 2014
«Coil 0» cross section
outer side inner side
Far from perfect, but this was a first test for the whole system!
Giovanni Volpini CERN, 1 July 2014

16. «Coil 1» under the optical measuring machine
Giovanni Volpini CERN, 1 July 2014

17. Giovanni Volpini CERN, 1 July 2014
Coil assessment
Test protocol
- Coil RT
Ground insulation test @ 5 kV (different techniques) > 8 Gohm
Dimensional measurements;
w/ gauge, w/ optical measuring apparatus
-> mould parts misaligned, tolerances of +/- hundredths seem feasible
Thermal LN on coil and on resin sample -> some crack in the coil, near bubbles, but not only. No crack in resin sample
Repeat resistance & ground insulation test -> OK
TBD
Inductance measurement
Cut & cross sections
Giovanni Volpini CERN, 1 July 2014

18. Giovanni Volpini, CERN 14 January 2014
Next steps
Design magnetic length cross-talk between magnets July 2014 fringe field (“harmonics” at the magnet ends) forces between magnets (March 2014) July 2014 Residual magnetization at I=0 and impact on the harmonics Cross check COMSOL results w/ Roxie (March 2014) Mechanical design (May 2014) September 2014 (new) conceptual design of all the magnets Construction & test Wind & impregnate a dummy coil (June 2014) Design the test cryostat (new) test coil w/ SC wire (July 2014) (new) next mould manufactured (Oct 2014)
Giovanni Volpini, CERN 14 January 2014

19. INFN-CERN Agreement approved by INFN board of directors in June ‘14,
to be signed by INFN President

21. thank you for your attention
Hint of the day:
festina lente!

22. Stored energy vs. At a6

23. Giovanni Volpini, CERN 19 June 2014
Quadrupole
891
460
yoke
coil
bore
Giovanni Volpini, CERN 19 June 2014

24. Iron yoke total length 800 mm
HX hole r = 185 mm
round bore flux return plate
Symmetric
flux return plate

25. Giovanni Volpini, CERN 19 June 2014
Design
Sextupole preliminary design
320
Yoke laminations machined by laser cut
followed by EDM (final accuracy 1/100 mm) on the relevant surfaces: poles, coil slots, alignment slots.
5.8 mm thick iron laminations
123
Giovanni Volpini, CERN 19 June 2014

26. Giovanni Volpini, CERN 19 June 2014
2700
ID 510
Giovanni Volpini, CERN 19 June 2014