1. LARP Collaboration Meeting Racetrack Coil Fabrication
Jesse Schmalzle, BNL
04/27/06
June 27, 2006
J. Schmalzle

2. SR Coil Fabrication
Two short racetrack (SR) coils fabricated using LBL supplied tooling and coil parts:
June 27, 2006
J. Schmalzle

3. SR Coil Fabrication
Coils assembled into LBL supplied support structure:
Bladder pressurized to 4500 psi (31 MPa).
Average shell stress = 7500 psi (52 MPa).
Preparing for cold test, estimate end of May.
June 27, 2006
J. Schmalzle

4. LR Coil Design
Long racetrack design closely matches that of short racetrack:
Double layer pancake made from single length of cable.
Transition between layers at lead end pole tip.
Iron pole coated with aluminum oxide.
Fiberglass sock cable insulation.
Pole width (uncoated) = mm (1.464 in.)
Coil straight section length = 3.45 m (136 in.)
Coil overall length = 3.61 m (142 in.)
June 27, 2006
J. Schmalzle

5. LR Coil Design
Variations as dictated by increased length /experience with SR coils:
Segmented pole – 5 segments
Allow for release of winding tension
Allow for differential expansion/contraction during reaction.
Gaps at reaction start = .42 mm/m minimum.
Full length stainless steel rails (SR used horse shoe).
Aluminum oxide thickness increased to 0.25 mm (.010 in.) (SR used .13 mm (.005 in.)).
Increased protection against shorts to pole.
June 27, 2006
J. Schmalzle

6. LR Coil Design Variations (continued):
Trace and glass cloth cover rails (covered coil only in SR).
Eliminate the need for precise cutting and placement that is required to cover the coil turns without covering the rails.
Glass cloth added between layers
Ease concern over greater potential for shorts between layers.
Reaction stack up, cavity set by pusher (tooling):
June 27, 2006
J. Schmalzle

7. LR Coil Design Variations (continued):
Instrumentation trace to include quench protection heaters.
Increase argon flow during reaction.
Improve removal of contaminates that may contribute to shorts to the pole.
Use higher flow rate below 400 C as palmitic acid is vaporized.
25 cfh up to 400 C, then drop to 10 cfh (SR was 3 cfh throughout).
Impregnation stack up, cavity set by pusher (tooling):
June 27, 2006
J. Schmalzle

8. LR Coil Design Coil Assembly:
G10 sheet and SST skin installed over impregnated coil.
Skins bolted to rails
Keys align individual pole segments.
Residual gaps in pole filled prior to impregnation.
G10 shims between coil and rails sized based on cable & part measurements.
Ends contained by pushers attached to rails.
June 27, 2006
J. Schmalzle

9. LR Coil Fabrication Insulated cable is transferred to winding spools:
Measured & divided onto 2 pancake spools.
One installed on winding machine carriage, other mounted above coil pole for use on second layer.
Cable vacuumed and checked for debris using lump detector.
Cable tension automatically monitored & controlled.
June 27, 2006
J. Schmalzle

10. LR Coil Fabrication Coil Winding:
Semi-automatic computer controlled winding machine
Existing machine, new platform and shuttle.
Pneumatic clamps to hold coil while opposite side is wound.
Wind on reaction base plate.
25 lbs cable tension.
June 27, 2006
J. Schmalzle

11. LR Coil Fabrication Reaction:
Shim coil and close fixture to provide ~1000 psi (7 MPa) side load.
Automatic computer controlled cycle.
Gas tight oven with continuously flowing argon atmosphere.
Supply fed directly into reaction fixture.
June 27, 2006
J. Schmalzle

12. LR Coil Fabrication Epoxy Impregnation:
Lead stabilizer solder fixture mounts to base plate.
Coil / Impregnation fixture to hang vertically in vacuum tank.
CTD 101K epoxy resin.
Automatic computer controlled cycle.
3 strip heaters/side–1500 Watts ea.
June 27, 2006
J. Schmalzle

13. LR Coil Fabrication Epoxy Impregnation: Fixture completely sealed.
Epoxy fed into bottom of fixture.
Outlet at top connected to resin trap.
Top of trap connected back to vacuum tank.
June 27, 2006
J. Schmalzle

14. LR Coil Handling Fixture Lifting:
Limit coil strain to less than .05% (1/4 of conductor strain limit)
Reaction & impregnation fixtures require only 2 point support.
Beams mount to sides of fixture in 2 places, lift from center.
Use for:
Transport
Up-righting
Flipping
Max Strain < .01%
Max deflection < .003” (.08 mm)
June 27, 2006
J. Schmalzle

15. LR Coil Handling Coil Lifting: Support Fixture Lifting:
Beam picks up coil using holes in rails.
Max strain < .01 %
Max deflection < .001” (.03 mm)
Support Fixture Lifting:
Collars clamped around shell.
Same beams / spreader as reaction & impregnation fixture lifting.
Up-right and hang in prep stand for connection to testing top hat.
Max strain < .01%.
Max deflection < .003” (.08mm).
June 27, 2006
J. Schmalzle

16. LR Coil Handling Prep Stand:
Hang impregnation tool for mounting to vacuum tank top plate.
Hang coil support structure for mounting to vertical cold test dewar top plate.
June 27, 2006
J. Schmalzle

17. LR Assembly Insertion of coils into support structure.
Existing long flat table.
Existing hydraulic cylinder
Coil insertion.
Bladder removal.
June 27, 2006
J. Schmalzle

18. LR Part / Tooling Status
Coil Parts:
Drawings released, shop is fabricating, completion estimate 4/28/06.
Winding machine shuttle and clamps:
Reaction tooling:
Drawings released, shop is ordering material.
Reaction oven:
Order placed with L&L, estimated delivery 7/7/06.
Impregnation tooling:
Drawings released, shop is estimating.
Fixture lifting beams & coil lifting beam:
Drawings released, material on order, completion estimate 5/30/06.
June 27, 2006
J. Schmalzle

19. LR Plan and Schedule Copper coil, estimate start winding 6/15/06.
Wind and impregnate only.
Required parts, expected dates:
winding machine, 5/25/06.
reaction base plate, 6/15/06.
coil parts, 5/30/06.
impregnation tooling, 6/22/06.
lifting fixtures, 5/30/06.
Coil Production, estimate start winding 8/7/06.
2 coils from good cable, 3rd if necessary.
reaction tooling, 7/14/06
reaction oven (installed & tested), 8/21/06.
Coil Assembly, estimate start 11/1/06.
Cold testing, estimate start 12/27/06.
June 27, 2006
J. Schmalzle