1. Bidders Conference Supply of a new control system and ancillary equipment for a Hydraulic Welding Press Friedrich Lackner 10/06/2015 F. Lackner / TE-MSC-LMF

2. List of Contents i.Short overview ii.Current press layout iii.New proposal for press layout (H. Prin) iv.Technical specification F. Lackner / TE-MSC-LMF

3. Supporting structure External conveyor Welding carriage Welding power source Large welding press in building 180 The Large Welding Press (length: 37,050 mm, width: 2,940 mm, height: 4,290 mm) F. Lackner / TE-MSC-LMF

4. Large welding press in building 180

5. Conveyance Friction wheels; Hydraulic motors (travel speed: 5 m/min); Guide rollers. Press structure 48 pressing cylinders (Force: 4 MN, stroke: 100 mm); 8 approaching cylinders (Force: 590 kN, stroke: 100 mm); 12 LVDT (Stroke: 50 mm, precision: ±0.05 %); Milling carriages (Cutting speed: 360-3000 rpm, travel speed: 0.2-200 mm/min); Welding carriages (Actuators, gun, seam tracker, teach pendant, wire feeder); Technical overview F. Lackner / TE-MSC-LMF Component product name: Pressing cylinder EPP COS400N100 Force: 4008 kNStroke: 100mm Approaching cylinder EPP COF60N100 Force: 590 kNStroke: 100mm Conveyor motor Samhydraulic BR80NC25 Travel speed: 5m/min

6. F. Lackner / TE-MSC-LMF Cross-sectional view of a superconducting dipole magnet; Left: Cold mass before operation, right: Sample (Diameter 580mm) Magnet cross-section:

7. This task is changing with the foreseen LMF projects Reparation and maintanance of magnets Welding of prototype magnets (short and long samples) Welding tests to confirm and validate shell stresses Possibility for a small series production Two main points for improvement: Minimizing the risk of hardware errors of all components (> 15 year old hard- and software); Bringing flexibility to the new tasks of the welding press. Requirement: 1.Simplifying the control complexity and hierarchy Bringing flexibility to the new tasks of the welding press; 2.Separation of hydraulic and welding unit; 3.Bringing possibilities for faster adaptation of hydraulic and welding parameters. Change of main tasks for the welding press: F. Lackner / TE-MSC-LMF

8. Base view F. Lackner / TE-MSC-LMF Layout:

9. Operating cycle F. Lackner / TE-MSC-LMF

10. With my documentation as a base, it is possible to outline a layout of the current Control System… Current Control System Layout F. Lackner / TE-MSC-LMF

11. Document “Description of the Large Welding Press” Layout of the Control System Conclusion Visions for a simplified Control System: ? F. Lackner / TE-MSC-LMF

12. Description of the LWP Layout of the Control System Ideas and Discussion Proposal: Pressing CS Layout with simplified exchange of information F. Lackner / TE-MSC-LMF

13. Description of the LWP Layout of the Control System Ideas and Discussion Proposal: Introduction / Extraction CS Layout with simplified exchange of information F. Lackner / TE-MSC-LMF

14. Safety Welding Power source Tracking Actuators Hydraulics Conveyance Loading- /unloading Approach Main cylinders in contact Pressing Cyclic pressuring Two separated Control Systems for hydraulic and welding: Future control architecture: F. Lackner / TE-MSC-LMF

15. Component Task: Light barriers Stop conveyance if interfered End switches Limit movements in x-, y- and z-axis Emergency shutdowns Switch off power supply for welding carriages Emergency trip wires Switch off power supply for welding carriages Differential Thermostats Control hydraulic oil temperature Proposals from suppliers ? Safety equipment, currently installed:

16. Current UI Start menu  Clear structure  Appears obsolete  Too much information  Mix of languages F. Lackner / TE-MSC-LMF

17. Introduction  Clear structure  Appears obsolete  No visualization Current UI F. Lackner / TE-MSC-LMF

18. Introduction Preconditions  Precise information,  Too much in case of no need,  Non-specialists have no link. Current UI F. Lackner / TE-MSC-LMF

19. Proposal for a new Hydraulics Display Outline Start menu Standardized bar on the basis of Windows programs Only “Observing Mode” until the admin password is entered F. Lackner / TE-MSC-LMF

20. Proposal for a new Hydraulics Display Outline Enter Password: Login OverviewConveyanceApproachPressingTable PositionHydraulic DiagramPreconditions EF F. Lackner / TE-MSC-LMF

21. HomeDataHelpLogout OverviewConveyanceApproachPressingTable PositionHydraulic DiagramPreconditions EF Save Approach Set Value [bar]: Actual Value [bar]: Pressure [bar] Unit 20 100 20 Reset Set Approaching unit Returns last saved values Magnet Type Length Status Approach started; Remaining lift time: 2:03 min Start Approach Un-/Lock Depressurise In-/Active Pause Not possible unless pressing is depressurised Short note F. Lackner / TE-MSC-LMF

22. Pressure [bar] Sectoring Side A Set Value [bar]: Actual Value [bar]: Sectoring Side B Magnet Type Length Pressing Pressing cylinder Set 320 20 Cylinder Pressure [bar] Cylinder 0 0 00 000000000000000000000000 000 0320 550 Set Value [bar]: Actual Value [bar]: 320 0 0 00 000000000000000000000000 0000 550 0 0 0000 00000000 00 0 0 0000 00000000 00 Current Sequence Select Sequence Actual pressure Set Start Pressing Un-/Lock Depressurise In-/Active Current Sequence Select Sequence Status Performing Pressure Sequence 1; Remaining dwell time: 2:03 min Next: Pressure Sequence 2 Pause Mouse-click opens pop-up window asking for confirmation HomeDataHelpLogout OverviewConveyanceApproachPressingTable PositionHydraulic DiagramPreconditions EF F. Lackner / TE-MSC-LMF

23. Magnet Type Length Pressure sequences Save 20 Actual Value [bar]: A01A02A03A04A07A08A09A10A05A06A15A16A17A18A21A22 A23 A24 A19 A20 A11A12A13A14 B01B02B03B04B07 B08 B09B10B05B06B15B16B17B18B21B22 B23 B24 B19 B20 B11B12B13B14 Side B Sequence 1 Sequence 2 Sequence 3 Sequence 4 … 0 0 0 0 55 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 … … … … … … … … … … … … … … … … … … … … … … … … Side A A01A02A03A04A07A08A09A10A05A06A15A16A17A18A21A22 A23 A24 A19 A20 A11A12A13A14 Side ASide B Sequence: Dwell Time: [min] Tolerance: [bar] 4 5 1 3 + - 4 5 1 3 Set Sequence 1 Sequence 2 Sequence 3 Sequence 4 … 0 0 0 0 55 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 … … … … … … … … … … … … … … … … … … … … … … … … B01B02B03B04B07B08B09B10B05B06B15B16B17B18B21B22 B23 B24 B19 B20 B11B12B13B14 0 0 0 0 55 0 0 0 0 Actual Value [bar]: 0 0 0 0 55 0 0 0 0 Back Reset HomeDataHelpLogout OverviewConveyanceApproachPressingTable PositionHydraulic DiagramPreconditions EF F. Lackner / TE-MSC-LMF

24. Introduction Optional:Proposal for a new Hydraulics Display Outline Conveyance Start/Stop Extraction Remote Status Ready Time left Start/Stop Motion HomeDataHelpLogout OverviewConveyanceApproachPressingTable PositionHydraulic DiagramPreconditions EF Automatic Manual F. Lackner / TE-MSC-LMF

25. Hydraulics Display Outline Hydraulic Diagram But those changes would lead to changes in the hydraulic circuit: F. Lackner / TE-MSC-LMF

26. [bar] 19.3 Actual value Changeable, Interactive position 4C12 4C 4C13 Energised Valve activeValve inactive Approaching circuit F. Lackner / TE-MSC-LMF Hydraulics Display Outline

27. F. Lackner / TE-MSC-LMF Hydraulics Display Outline