1. Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets CERN AT-MTM 1 / 21 O. DUNKEL CERN – Geneva – CH olaf.dunkel@cern.ch 14th International Magnetic Measurement Workshop 26-29 September 2005, Geneva, Switzerland Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets at CERN R. Beltron, J. Billan, O. Dunkel, L. Gaborit, P. Galbraith, J. Garcia-Perez, D. Giloteaux, B. Girod

2. Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets CERN AT-MTM 2 / 21 O. DUNKEL CERN – Geneva – CH olaf.dunkel@cern.ch 14th International Magnetic Measurement Workshop 26-29 September 2005, Geneva, Switzerland Activities Dipole Moles DIMM AC-Mole Level meter Calibration Quadrupole QIMM Block 4 Sectors Connector Radius Parallelism Gradient Long shafts Optical Mole Coils Soft soldering Assembly Coil area surface

3. Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets CERN AT-MTM 3 / 21 O. DUNKEL CERN – Geneva – CH olaf.dunkel@cern.ch 14th International Magnetic Measurement Workshop 26-29 September 2005, Geneva, Switzerland Contents

4. Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets CERN AT-MTM 4 / 21 O. DUNKEL CERN – Geneva – CH olaf.dunkel@cern.ch 14th International Magnetic Measurement Workshop 26-29 September 2005, Geneva, Switzerland Coil Manufacture – semi-automatic Single wire Ø 30µm - 150µm [up to 1mm for solenoids] Coil length from 18mm to 260mm Coil width up to 30mm (more if needed) Up to 3.000 turns (and more…) [up to 30.000 turns for solenoids] Coil cores from G10, Delrin (in general) Winding machines for race track, solenoid and toroidal coils Race track [and solenoid] coils: Toroidal coils: Meteor M101 B FUR DBA-S Single wire Ø 0.08mm to 1.8mm Single or multi-layer, with separators Core inner Ø 30mm min. Core outer Ø 200mm max. Various materials for coil cores

5. Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets CERN AT-MTM 5 / 21 O. DUNKEL CERN – Geneva – CH olaf.dunkel@cern.ch 14th International Magnetic Measurement Workshop 26-29 September 2005, Geneva, Switzerland Coil Manufacture – semi-automatic Pickup coils from 18 to 260mm length Toroidal coil in winding process Toroidal coils ready for delivery Coil realizations on winding machines Solenoid for a cryogenic valve 60 mm 50 mm 100 mm 280 mm

6. Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets CERN AT-MTM 6 / 21 O. DUNKEL CERN – Geneva – CH olaf.dunkel@cern.ch 14th International Magnetic Measurement Workshop 26-29 September 2005, Geneva, Switzerland Coil Manufacture – manual Multi-filament wire, up to 20 filaments Ø 60µm Coil length from 260mm to 2000mm Coil width up to 15mm (more if needed) Up to 20 turns (square shaped cross section) Coil cores from G10 (in general) Selection of coils wound manually Manual coil winding facility Multi filament cable Rotating support Epoxy bond reservoir Coil core 250 mm

7. Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets CERN AT-MTM 7 / 21 O. DUNKEL CERN – Geneva – CH olaf.dunkel@cern.ch 14th International Magnetic Measurement Workshop 26-29 September 2005, Geneva, Switzerland Coil Manufacture – manual Coil winding Rotating support for coil core Wire folding Polymerization 15 mm

8. Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets CERN AT-MTM 8 / 21 O. DUNKEL CERN – Geneva – CH olaf.dunkel@cern.ch 14th International Magnetic Measurement Workshop 26-29 September 2005, Geneva, Switzerland Coil Manufacture – manual Various multi – filament wires 6 strands8 strands 10 strands20 strands

9. Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets CERN AT-MTM 9 / 21 O. DUNKEL CERN – Geneva – CH olaf.dunkel@cern.ch 14th International Magnetic Measurement Workshop 26-29 September 2005, Geneva, Switzerland Coil Manufacture Cross section of multi-filament race track coils Cross section of a single wire, race track coil, 1000 turns 6 strands 36 turns 20 strands 400 turns Coil cross sections 0.5 mm

10. Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets CERN AT-MTM 10 / 21 O. DUNKEL CERN – Geneva – CH olaf.dunkel@cern.ch 14th International Magnetic Measurement Workshop 26-29 September 2005, Geneva, Switzerland Coil interconnection and cabling -Manual soft soldering under binocular -Connection plates for each type of cable (single wire Ø 32µm to 20 strand wire) -Soft soldering of signal cables to coils -Connection of signal cables to external connector Binocular used for soft soldering Various connection plates

11. Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets CERN AT-MTM 11 / 21 O. DUNKEL CERN – Geneva – CH olaf.dunkel@cern.ch 14th International Magnetic Measurement Workshop 26-29 September 2005, Geneva, Switzerland Coil interconnection and cabling Example of an Interconnection scheme: 10 strand wire in a 20 strand connection plate Connection plates embedded in coil core, left: single wire, right: 20 strand wire Preparation for soft soldering of a 20 strand connector Signal cables connected to their coils All coils of a sector connected 4 mm 12 mm 10 mm 50 mm

12. Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets CERN AT-MTM 12 / 21 O. DUNKEL CERN – Geneva – CH olaf.dunkel@cern.ch 14th International Magnetic Measurement Workshop 26-29 September 2005, Geneva, Switzerland Measuring Head Assembly -Sectors for long shafts (high field probes) used for cold measurements of LHC dipoles and SSS -3/5 race track coils (2/4 tangential, 1 central), length: 700-1200mm -Coil support: ceramics (Al 2 O 3 ) Cross section of a sector for dipole measurements Sectors for long shafts: Subminiature electrical connectors Parts to be assembled Assembled dipole shaft: 13 sectors + 1 prolongation = 18.5m 37 mm 1300 mm

13. Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets CERN AT-MTM 13 / 21 O. DUNKEL CERN – Geneva – CH olaf.dunkel@cern.ch 14th International Magnetic Measurement Workshop 26-29 September 2005, Geneva, Switzerland Measuring Head Assembly -Low field probes used for warm magnetic measurements on dipoles and quadrupoles during magnet production in industries. -3/5 race track coils (radial) for dipoles, coil length: 750mm -Coil support: G10 -Level meter, slip rings, pneumatic brake, rotating motor unit, etc. Moles for Warm and Cold Measurements: AC-Moles: -High and low field AC probes used for geometric and magnetic axis measurements of LHC dipoles and quadrupoles -4 tangential race track coils, coil length: 116mm -Coil support: G10 -Level meter, camera, corner cube, rotating motor, slip rings, etc. AC Mole Parts and assembled DIMM-Mole 1500 mm

14. Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets CERN AT-MTM 14 / 21 O. DUNKEL CERN – Geneva – CH olaf.dunkel@cern.ch 14th International Magnetic Measurement Workshop 26-29 September 2005, Geneva, Switzerland Measuring Head Assembly Heads and shafts for cold mass measurements in LHe: -High field probes used for harmonic and Gdl measurements on cold masses for SSS and corrector magnets, operating in liquid Helium. -3/5 radial race track coils, coil length: 200mm to 1200mm -Coil support: G10 Shaft during assembly Parts and assembled shaft for measurements in LHe 1200 mm 250 mm

15. Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets CERN AT-MTM 15 / 21 O. DUNKEL CERN – Geneva – CH olaf.dunkel@cern.ch 14th International Magnetic Measurement Workshop 26-29 September 2005, Geneva, Switzerland Measuring Head Assembly Prototyping and repair workshop: Turning… …milling… …drilling Adjustment table for Level meters Dynamic gluing table UV curing for coil gluing

16. Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets CERN AT-MTM 16 / 21 O. DUNKEL CERN – Geneva – CH olaf.dunkel@cern.ch 14th International Magnetic Measurement Workshop 26-29 September 2005, Geneva, Switzerland Magnetic Calibration The laboratory: Short reference quadrupoles [0.3m, 0.5m] Reference dipole [2.5m] Power supply for reference dipole Reference quadrupole [1.5m] 15m cryodipoleAssembly Soft soldering Grinding -Several reference magnets installed in former ISR tunnel, good stabilization in temperature

17. Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets CERN AT-MTM 17 / 21 O. DUNKEL CERN – Geneva – CH olaf.dunkel@cern.ch 14th International Magnetic Measurement Workshop 26-29 September 2005, Geneva, Switzerland Dipole reference magnet: -Effective aperture: l=2.5m, h=80mm, w=300mm -Field: 1T (stab.:10 -5 T), monitored continuously with NMR probe and periodically mapped -Field angle aligned to <0.1 mrad w/r gravity -Used for calibration of coil area, parallelism and absolute angle (up to 5 coils simultaneously) -Overall uncertainty: 2x10 -4 (repeatab.: 5x10 -5 ) Magnetic Calibration Dipole Rotation support Integrators and PC NMR probe Quadrupole reference magnet: -Magnet aperture: l=1.5m, Ø 125mm, -Field gradient of 8.6 T/m (@ 480 A) -Used for calibration of coil radii (up to 5 coils simultaneously) -Overall uncertainty: 5x10 -4 Quadrupole Integrators and PC Rotation and centering support Lateral stroke Sensor (res. 10 -3 mm)

18. Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets CERN AT-MTM 18 / 21 O. DUNKEL CERN – Geneva – CH olaf.dunkel@cern.ch 14th International Magnetic Measurement Workshop 26-29 September 2005, Geneva, Switzerland Magnetic Calibration 15 m LHC Cryodipole: -Mainly used for checks and improvements of warm measurement systems running in cold mass factories (real size checks) -No diode mounted  no polarity limitation -Current limited to 15 A -First checks on reference magnet system (RMS) for LHC machine magnets Short Reference Quadrupole: DIMM-Mole measurements in 15m cryodipole AC-Mole measurements in short reference quadrupole -Magnet aperture: l=0.285m, Ø 70mm -Field gradient of 18.1 T/m (@ 352 A) max. w. cooling -Mainly used for magnetic and geometric calibration of global and optical AC moles Calibration Results: -Calibration sheet  Traveller  Database

19. Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets CERN AT-MTM 19 / 21 O. DUNKEL CERN – Geneva – CH olaf.dunkel@cern.ch 14th International Magnetic Measurement Workshop 26-29 September 2005, Geneva, Switzerland Outlook -Improvement of accuracy on Gdl calibration procedure -Extension of magnetic and optical calibration facilities for AC Moles -Development and tests of Reference Magnet System (RMS) for LHC machine magnets -Extension of magnetic and optical calibration facilities for AC Moles -… life after LHC …??? What comes next?

20. Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets CERN AT-MTM 20 / 21 O. DUNKEL CERN – Geneva – CH olaf.dunkel@cern.ch 14th International Magnetic Measurement Workshop 26-29 September 2005, Geneva, Switzerland Where are we at CERN? Coil Manufacture, Assembly and Calibration Facility CERN, bldg. 230

21. Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets CERN AT-MTM 21 / 21 O. DUNKEL CERN – Geneva – CH olaf.dunkel@cern.ch 14th International Magnetic Measurement Workshop 26-29 September 2005, Geneva, Switzerland Where are we at CERN? Thank you for your kind attention… Come and visit…!