1. Baby MIND coil modules assembly the aluminium folded strip solution 1 Alexey, Philippe, Gabriella, Helder, Herman Baby Mind Magnet Meeting @ CERN June 10, 2015

2. 1. Design and assembly strategy Magnetic design drastically adapted and optimized to get the field in the detector area as uniform as possible with minimum “loss of magnetics”, optimum flux return, no gaps between coil and plate (see presentation on magnetic design). Magnetic steel plates are delivered clean and/or shot blasted, but are not perfectly flat, and the coil manufacturing is adapted accordingly. To avoid gap filling and shimming, the coil turns are directly assembled on the plate with proper insulation in between. The design is robust, using simple tools and requiring minimum labour for making final coil modules in one-go. Aluminium strips are folded into single turns either at CERN by outside contractor. Drilling in plates is done either at CERN or by outside contractor. 2

3. 2. Assembly tools, to be procured or borrowed Vertical supports for 3 or 4 assembly benches. Lifting and turnover brackets and a local crane. Magnetic knobs to pressure parts onto the steel plates. Material and tools for work with epoxy resin. Magnetic drilling machines and drilling jig for local drilling on site (when done at CERN). Strip bending tool (when done at CERN). 3 Plate drilling, strip folding and final magnet assembly have to be discussed separately. This presentation shows the manufacturing proposal for the 40 coils, making up the 20 magnet modules.

4. 3. Coil manufacturing shows 3 main activities 4 (1) Plate drilling (2) Strip folding (3) Coil assembly

5. 4.1 Coil assembly Estimated time indicated in hour (h) 1.Place steel plate on support (2h). 2.Cleaning allowing resin bonding (2h). 3.Gluing of side insulation films (4h). 5

6. 4.2 Coil assembly 1.Place steel plate on support 2.Cleaning 3.Gluing of side insulation films 4.Install and glue top and bottom insulation and turn-guiding strips (shim if needed) (2h). 6

7. 4.3 Coil assembly 1.Place steel plate on support 2.Cleaning 3.Gluing of side insulation films 4.Install and glue top and bottom insulation and turn-guiding strips (shim if needed) (1/4) 5.Put in place Al folded single turns one by one and lock with a bolt (4h). 3 and 4 mm thick elements are made 7

8. 4.4 Coil assembly 1.Place Iron plate on support 2.Cleaning 3.Gluing of side insulation films 4.Install by gluing top and bottom insulation and turn-guiding strips (shim if needed) (1/4) 5.Put in place Al folded single turns one by one and lock with a bolt (1/4) 6.Install, glue and cure side insulation plates, use magnets to close gap with the iron plate (4h). 7.Turn and move to the storage and welding position (2h). 8

9. 4.5 Coil assembly 1.Place Iron plate on support 2.Cleaning 3.Gluing of side insulation films 4.Install by gluing top and bottom insulation and turn-guiding strips (shim if needed) (1/4) 5.Put in place Al folded single turns one by one and lock with a bolt (1/4) 6.Install, glue and cure side insulation plates, use magnets to close gap with the iron plate (/) 7.Turn and move to the storage and welding position (1/4) 8.Add heat sink, weld and clean (4h). 9.Final insulation on narrow sides and add coil screw terminals (4h). 9 3 and 4 mm thick strips welded, temperature is OK

10. 5. Space, manpower and time It’s about 30 h, or nearly 4 days per coil so 4 benches are needed to make 1 coil per day, involving 3 technicians, 2 for handling the large objects and 1 for preparations. 10

11. 6. Conclusion and outlook 11 A practical, simple and robust coil manufacturing method was developed based on coil winding directly on the steel plate. Recommended next step is to make a full-size dummy (in Sept-Oct) to collect all tooling, exercise the assembly steps, qualify the mechanical and electrical design, train the technicians for the job. When done a better estimate of the work load for the production of the 40 coils can be made, commit the team and prepare the production area. Production can probably start in April 2016 provided steel plates delivered.