Helene Felice, Dan Cheng Support structure modifications Update on discussion at CERN

Content of the discussion at CERN Structure: Component by component Component dimensions Holes, bushings, rods size Key sizes Tolerances Alignment features Assembly procedure (somewhat) Integration options CERN welded half-shells BNL inertia tube 209/09/2013H. Felice

QXF cross-section (09/04/2013) collar pad Pad master Yoke master Yoke Al shell SS LHe containment half shell Pin for alignment Alignment key Pole key 309/09/2013H. Felice

Integration features (CERN option) 409/09/2013H. Felice

Alignment features collarpadPad masterYoke masteryokeshellSS LHe container CoilG10 key CollarMidplane Indent padTrapezoidal shape pmasterAlignment key ymasterTrapezoidal shape yokeMidplane pin shellC shape clamp – weld shrinkage (CERN) or through supports (BNL) Concern about the number of components Minimizing it would reduce tolerance build-up 509/09/2013H. Felice

Component by component From collar out: 09/09/2013H. Felice6

COLLAR (I) IR of the collar has been fixed to 115 mm which accounts for Nominal coil OR after impregnation is mm (baseline) Wide coil ( mm) OR after impregnation is mm Trace + insulation mm Decision on the length of the structure to m (CAD) Coil length (endshoe to extension): 1.51 m m of coil length variability (not in CAD) m of G10 pushers (0.01 per side in CAD) m of SS pusher (0.01 m per side in CAD) will be inside structure in CAD model (no variability accounted for) Might be flush with structure or sticking out depending on coil length variability. Lamination thickness: 50 mm => 31 collar laminations Alignment feature at the midplane will be female on the collar side 709/09/2013H. Felice

COLLAR (II) Bolting of the collar: M6 bolts Slotted hole will be open to avoid thin wall thickness Through hole with shorter length thread Tie rod holes will be moved (same center radius, few degrees down) to ensure enough wall thickness between tie rod hole and the bolt hole (at least 3 mm) M6 tie rods Bushings chosen accordingly A profile tolerance will be given for the collars laminations (FR: tolerance de forme) as all the surfaces are important surfaces 809/09/2013H. Felice

Pole key Pole groove is 14 mm Collar distance 15 mm 0.5 mm per side to include ground plane insulation and key shimming Key nominal width is 14-2x0.625 = mm 909/09/2013H. Felice

Proposal To merge the pad and the pad master Maintain a free alignment key Maintain yoke master Pros: remove 1 component Cons: Assembly procedure Would probably require to install the yoke master before insertion of the coil pack Having enough clearance for coil pack insertion Need to quantify impact on field quality See Franck slides Ongoing discussions at LBNL Vertical alignment Horizontal alignment 1009/09/2013H. Felice

PAD and MASTERS (I) Pad and pad master might be merged in a unique component Yoke master will remain a separate component from the yoke Making it part of the yoke would prevent loading by quadrant and prevent aligning coil pack to yoke during loading The alignment key will be a separate component Making it part of the pad could make the assembly more difficult the alignment key will be made wider Will be brass Load keys will be stainless steel Slot and spacing to be defined 1109/09/2013H. Felice

YOKE (I) Note about the laminations: Moving outward radially in the structure, collars, pads and yoke are laminated Longitudinally the stack of laminations should be offset-ed moving outward from the collar to the pad: The 1 st collar and yoke lamination will be 50 mm laminations The 1 st pad lamination will be a 25 mm lamination Yoke keys: Clearance around the key in the slot > 0.5 mm (all directions) a> or = 6 mm b ~ 3 mm Yoke key ~ 11 (height) by 8 mm (wide) Bruno will check for the standard a b 1209/09/2013H. Felice

YOKE (II) Yoke alignment/integration features When present, should be present in all 4 quadrants Need only to be present in extremities laminations In between could be plain laminations Geometry of the features to be discussed with Herve Prin/Mike Anerella  Magnetic and mechanical impact on the design has to be checked Lamination assembly: Decision to go with M18 tie rods and 22 mm bushings/holes Standard to be checked 1309/09/2013H. Felice

SHELL Shell alignment/integration features When present, should be present in all 4 quadrants Geometry of the features to be discussed with Herve Prin/Mike Anrella  Mechanical impact on the design has to be checked: 3D 1409/09/2013H. Felice

PAD and MASTERS (II) If pad master and pad combined: Yoke master will have to get thicker to incorporate bladders junction blocks Junction block dim to be finalized (2 mm of wall thickness) More material could be obtained by reducing the pad radial thickness (now thicker because merged with the pmaster) and moving the yoke master edge inward Junction block dimension has to be agreed on if bladders are procured separately by LBL and CERN. LBNL is using 9.5 mm 1509/09/2013H. Felice

END PLATE and RODS Baseline plate is 75 mm thick Scaled up from HQ (60 % more axial forces in QXF) Aperture will be 150 mm in diameter M16 “real” bullets (spherical end) will be used instead of set screws (HQ) Distance between endplate and face of the yoke is set to 25 mm LARP experience is 35 mm Rods M33 have to be elongated in present CERN CAD model to allow for spherical washer and 2 nuts Thread on rods will be asymmetric for lead and return ends (to allow for axial load rig (endplate, piston…) mounting) Axial load rig will be assembled on return end (non connection) side => Should be added to the CAD model 1609/09/2013H. Felice

Analysis to be performed ANSYS 2D model Incorporate pad master in pad Modify tie rod hole (22 mm) Change alignment feature between pad and collar (female) Modify yoke master thickness to accommodate junction blocks Master=15 mm wide 3 mm deep bladder slot 12 mm bladder wall Accommodates 9.5 mm junction block allowing 2 mm wall thickness Set pad to yoke master minimum distance = 3mm Impact of yoke features on magnetic and mechanical analysis Opera 2D / Roxie to be defined 1709/09/2013H. Felice

Overview of the 08/29/2013 meeting with CERN: Herve Prin, Frederic Savary, Paolo Ferracin, Juan Carlos Perez, Mariusz Juchno BNL: Mike Anerella Integration

LARP Deliverable Q1 and Q3 are the magnets to be delivered by LARP (2 ~ 4m long magnet per cold mass From Budget prepared by Mike et al., LHe containment not included in the deliverable Based on recent discussion with G. Apollinari, it seems that the question is still open Aluminum shell magnet Or with SS LHe containment 2 main solutions 2 half shells welded together at the midplane => proposed by CERN Insertion in inertia tube => proposed by BNL 09/09/2013H. Felice19

CERN option Main concerns Weld contamination by Aluminum Presently a groove/cut out is designed in the shell to allow for Argon flow and ensure the quality of the weld Aluminum shell damage, potentially melting locally during winding Two half-shells welded around the Al shell Contact between Al and SS shells Tension in SS shell provided by weld 09/09/2013H. Felice20

BNL Option 09/09/2013H. Felice21 Inertia tube Gap between Al and SS shells Main concerns Clearance needed to insert magnet in inertia tube Action item: Show concept on baseline structure How do we proceed?

Next steps LARP and CERN ANSYS 2D model Impact of yoke features on magnetic and mechanical analysis Opera 2D / Roxie to be defined LARP Integration (LARP) BNL option applied to baseline structure 09/09/2013H. Felice22