Dan Cheng H. Felice, R. Hafalia QXF Structures Video Meeting July 10, 2014 Coil Handling for Magnet Assembly Status Update

Outline 7/10/2014Magnet Assembly Coil Handling2 Assembly requirements & constraints Status update since the CM

Assembly Requirements, Coilpack Handling 7/10/2014Magnet Assembly Coil Handling3 Impregnated Coil Parameters – OD: mm; ID: mm – Length: SQXF: 1.5 m LQXF: 4.3 m – Weight: SQXF ~130 lbs / 60 kg LQXF ~375 lbs / 170 kg Handling operation requirements – Single coils, bore-side down – Single coils, bore-side up – Coil pairs, bore-side down – Coil pairs, bore-side up – Eliminate manual coil flipping operations – Accommodate and install alignment keys & shims, Ground Plain Insulation (GPI) at assembly – Accommodate bore-side instrumentation (SGs, etc.) at assembly

LARP Magnet Assembly Experience 7/10/2014Magnet Assembly Coil Handling4 Tooling and processes developed from prior magnets – Based on experience from TQS, HQ, LR, LQ Utilizes already-designed tooling – FNAL rollover tooling designs, with some design modifications – Existing lifting hardware (SQXF, LQ, etc.) Differences expected in QXF assemblies: – GPI installation will be incorporated in these coils – SQXF handling tooling should be scalable towards LQXF and production assemblies

7/10/2014Magnet Assembly Coil Handling5 BNL Lifting Tooling Update Fixture has been re-analyzed by BNL Safety sign-off and proof load test at LBNL is in process

7/10/2014Magnet Assembly Coil Handling6 FNAL Coil Rollover Tool Modifications Modify cradle for SQXF diameters Add cradle cutouts at 45°, 2 places Move support rollers inboard, 2 places Create new coil support mandrels Two wheel set pairs required for SQXF coil handling operations (four wheels total) Six to eight wheels sets may be needed for LQXF

7/10/2014Magnet Assembly Coil Handling7 Rollover Assembly, Modified FNAL Removable “shelf” support for coil midplanes Supports can be adjusted to optimize longitudinal position Pins and/or screws for positively positioning coils Mandrel and lifting beam to have silicon rubber layers for protecting coil

7/10/2014Magnet Assembly Coil Handling8 Rollover Assembly, Modified FNAL

7/10/2014Magnet Assembly Coil Handling9 GPI Scheme Updated

Tooling and Assembly Concept Summary 7/10/2014Magnet Assembly Coil Handling10 Conceptual SQXF coilpack assembly steps presented at CM is currently unchanged – See additional slides (or CM presentation) – GPI scheme has been simplified since CM Status – BNL designed lifting tooling is in process of being qualified – Rollover tooling is in procurement stages 4 sets to be purchased for SQXF Additional sets can be purchased for LQXF operations

Additional Slides 7/10/2014Magnet Assembly Coil Handling11

7/10/2014Magnet Assembly Coil Handling12 Coil Prep, From Shipping to Instrumentation Operation: – Clamp rings placed over coil Coil will have: – VT wires attached – No SGs or GPI

7/10/2014Magnet Assembly Coil Handling13 Coil Prep, From Shipping to Instrumentation Operation: – Wheel assembly rotated 180° Coil will have: – VT wires attached – No SGs or GPI

7/10/2014Magnet Assembly Coil Handling14 Coil Prep, From Shipping to Instrumentation Operation: – Clamp & mandrel removed Coil will have: – VT wires attached – No SGs or GPI

7/10/2014Magnet Assembly Coil Handling15 Coil Prep, From Shipping to Instrumentation Operation: – Lifting “spuds” placed onto coil Lifting spuds attached in three locations Coil will have: – VT wires attached – No SGs or GPI

7/10/2014Magnet Assembly Coil Handling16 Coil Prep, From Shipping to Instrumentation Operation: – Coil lifting beam brought to coil Recycled LQ coil lifting strongback (~3.3 m) Redesigned coil interfaces, 3 places Coil will have: – VT wires attached – No SGs or GPI

7/10/2014Magnet Assembly Coil Handling17 Coil Prep, From Shipping to Instrumentation Operation: – Beam and “spuds” engaged via inserted pins Pin engagement through hole in tooling and spud Coil will have: – VT wires attached – No SGs or GPI

7/10/2014Magnet Assembly Coil Handling18 Coil Prep, From Shipping to Instrumentation Operation: – Coil lifted and moved to work area Later steps not shown: Strain gage installation, Wiring & connectorization, QA Coil will have: – VT wires attached – No SGs or GPI

Between receiving coils and assembly, a number of steps will have occurred (but not described here) – Coils will be instrumented with SGs – Wiring and connectors will be added – Coil QA will be performed – Coils will go into storage trays, bore-side up 7/10/2014Magnet Assembly Coil Handling19 Intermediate Coil Steps, Before Assembly

7/10/2014Magnet Assembly Coil Handling20 Coil Prep, From Storage to GPI Installation Operation: – Coil placed into rotation wheel Steps not shown: Coil lifted and moved from storage tray Coil will have: – VT wires attached – SG & wires on bore-side – No GPI Strain gages and wiring will be mounted on bore-side

7/10/2014Magnet Assembly Coil Handling21 Coil Prep, From Storage to GPI Installation Operation: – Mandrel & clamps installed over coil Coil will have: – VT wires attached – SG & wires on bore-side – No GPI (Alternate clamping mandrel pictured here) Clearances for SG wiring not shown

7/10/2014Magnet Assembly Coil Handling22 Coil Prep, From Storage to GPI Installation Operation: – Rotation wheel rotated 180° Coil will have: – VT wires attached – SG & wires on bore-side – No GPI

7/10/2014Magnet Assembly Coil Handling23 Coil Prep, From Storage to GPI Installation Operation: – Clamps removed from around coil Coil will have: – VT wires attached – SG & wires on bore-side – No GPI

7/10/2014Magnet Assembly Coil Handling24 GPI, Alignment Key Installation Operation: – GPI and alignment keys installed Relief clearances required for GPI installation For diagram purposes only. GPI & Alignment key (and shims)installation detailed in GPI talk (Jesse) and coil assembly talk (Helene)

7/10/2014Magnet Assembly Coil Handling25 Coilpack Assembly, Pairing Bottom Coils Operation: – Move coil from 2 nd rotation wheel Coil will have: – VT wires attached – SG & wires on bore-side – GPI and alignment key Second Rotation wheel assembly

7/10/2014Magnet Assembly Coil Handling26 Coilpack Assembly, Pairing Bottom Coils Operation: – Rotate coil by 45° Coil will have: – VT wires attached – SG & wires on bore-side – GPI and alignment key Note: Coil may have clamps installed, or may be bolted thru during rotation operation

7/10/2014Magnet Assembly Coil Handling27 Coilpack Assembly, Pairing Bottom Coils Operation: – Pick up second coil with GPI/key Coils will have: – VT wires attached – SG & wires on bore-side – GPI and alignment key

7/10/2014Magnet Assembly Coil Handling28 Coilpack Assembly, Pairing Bottom Coils Operation: – Mate second coil to the first one at 45° Coils will have: – VT wires attached – SG & wires on bore-side – GPI and alignment key

7/10/2014Magnet Assembly Coil Handling29 Coilpack Assembly, Pairing Bottom Coils Operation: – Mate second coil to the first one at 45° Coils will have: – VT wires attached – SG & wires on bore-side – GPI and alignment key

7/10/2014Magnet Assembly Coil Handling30 Coilpack Assembly, Pairing Bottom Coils Operation: – Replace clamps and rotate coils 135° Coils will have: – VT wires attached – SG & wires on bore-side – GPI and alignment key

7/10/2014Magnet Assembly Coil Handling31 Coilpack Assembly, Pairing Bottom Coils Operation: – Remove clamps and mandrel support Coils will have: – VT wires attached – SG & wires on bore-side – GPI and alignment key

7/10/2014Magnet Assembly Coil Handling32 Coilpack Assembly, Pairing Bottom Coils Operation: – Attach lifting beam to coil pair Coils will have: – VT wires attached – SG & wires on bore-side – GPI and alignment key Clamps may need to be removed during lifting operation, due to presence of alignment keys Clearances for SG wires may be necessary

7/10/2014Magnet Assembly Coil Handling33 Coilpack Assembly, Pairing Bottom Coils Clamps may need to either be modified, or removed during lifting operation, due to presence of alignment keys Operation: – Lift coil pair; move to collar stack Coils will have: – VT wires attached – SG & wires on bore-side – GPI and alignment key

7/10/2014Magnet Assembly Coil Handling34 Coilpack Assembly, Pairing Bottom Coils (HQ) First collar stack Operation: – Place coil pair onto collar stack Coils will have: – VT wires attached – SG & wires on bore-side – GPI and alignment key Collars will have: – Additional Kapton/G11 layers

7/10/2014Magnet Assembly Coil Handling35 Coilpack Assembly, Pairing Upper Coils Operation: – Rotate coils by 45° opposite direction Coils will have: – VT wires attached – SG & wires on bore-side – GPI and alignment key

7/10/2014Magnet Assembly Coil Handling36 Coilpack Assembly, Pairing Upper Coils Operation: – Align coil pair lifting strongback Coils will have: – VT wires attached – SG & wires on bore-side – GPI and alignment key

7/10/2014Magnet Assembly Coil Handling37 Coilpack Assembly, Pairing Upper Coils Operation: – Attach coil pair lifting strongback Coils will have: – VT wires attached – SG & wires on bore-side – GPI and alignment key

7/10/2014Magnet Assembly Coil Handling38 Coilpack Assembly, Pairing Upper Coils Recycled LQ coil pair lifting strongback (~3.3 m) Hold down tooling (bolts, pins) may have to be removed before coils can be lifted Operation: – Lift coil pair with lifting strongback Coils will have: – VT wires attached – SG & wires on bore-side – GPI and alignment key

7/10/2014Magnet Assembly Coil Handling39 Upper Coils & Collaring Assembly (HQ) Operation: – Mate coil pairs together – Support with angle irons Coils will have: – VT wires attached – SG & wires on bore-side – GPI and alignment key

7/10/2014Magnet Assembly Coil Handling40 Upper Coils & Collaring Assembly (HQ) Operation: – Bolt collars (with shims, GPI, etc.) – Bolt load pads Coils will have: – VT wires attached – SG & wires on bore-side – GPI and alignment key Collars will have: – Additional Kapton/G11 layers

7/10/2014Magnet Assembly Coil Handling41 Coilpack Assembly, Collar Assembly (HQ) Operation: – Coilpack ready for insertion

Tooling and Assembly Concept Summary 7/10/2014Magnet Assembly Coil Handling42 Conceptual SQXF coilpack assembly steps presented – Key interfaces identified at operation stages Reuses exiting tooling designs – LQ lifting hardware (for SQXF), however for LQXF may require new tooling – FNAL rollover tooling will have modifications made to accommodate the SQXF coils Scalability – Both SQXF rollover tables can be reconfigured to accommodate one LQXF coil, and one more set can be purchased for the second rollover assembly needed in LQXF – LQ lifting hardware can either be extended to accommodate 4.3m long coils, or… – (Preferable) New, dedicated strongbacks can be designed