CNGS Horns : Status 8 nov. 2003 NBI 2003 – KEK, Japan 7-11 nov. 2003 NBI 2003 - CNGS Horns Status 1 Presented by Sandry Wallon
CNGS Horns : Status CONTENT 1 .O u t l i n e o f t h e c o n t r i b u t i o n 2 .D e s i g n & s t u d i e s 3 .M a n u f a c t u r e & c h e c k i n g s 4 .M o u n t i n g & a d j u s t m e n t s 5 .S u m m a r y NBI 2003 - CNGS Horns Status 2 Presented by Sandry Wallon
1. O u t l i n e o f t h e c o n t r i b u t i o n P i o n s a n d k a o n s f o c u s e d b y 2 m a g n e t i c h o r n s t o w a r d G r a n S a s s o French contribution • 2 horns (included 1 spare horn) • 1 reflector • 2 cooling systems • 2 strip lines w/ fast coupling system • 2 sets of adjustable supports NBI 2003 - CNGS Horns Status 3 Presented by Sandry Wallon
2. Design & studies 7.5 m long 1600 kg of aluminium alloy (+ ceramic, stainless steel, …) 7.5 m long Double pulses within 50 ms 2200 kg Pulse duration : 6 ms (horn) 13 ms (reflector) 6 s cycle during 4 years (2 10 7 pulses) 150 kA (peak), 5000 A RMS Toroidal B field : 1.9 T max. NBI 2003 - CNGS Horns Status 4 Presented by Sandry Wallon
2. Design & studies Full 3D design Horn NBI 2003 - CNGS Horns Status 5 Presented by Sandry Wallon
2. Design & studies Other equipement Set of 3 adjustable supports Fast Coupling System & striplines inside chamber / gallery Fast Coupling System (FCS) Striplines and FCS new design Strip lines ⇒ Worker’s protection during loosening / tightening FCS (shielded chicane) ⇒ Better confidence in FCS functionality Not shown : cooling system NBI 2003 - CNGS Horns Status 6 Presented by Sandry Wallon
2. Design & studies Misc. studies done to guaranty functionalities (especially for horn’s inner conductor) • Thermal : Deformation & Stress. Status Done • Static : Straightness. • Stability : Buckling. • Dynamic : Fatigue-corrosion (4 years lifetime requested). NBI 2003 - CNGS Horns Status 7 Presented by Sandry Wallon
2. Design & studies ⇒ material behavior Thermal study ⇒ thermal expansion, stresses Heat load (inner cond.) • 13 kW (Joule losses) • 5 kW (radiation) Water curtain falling onto inner conductor NBI 2003 - CNGS Horns Status 8 coeff convection Presented by Sandry Wallon
2. Design & studies Thermal study ∆ T = 5 °C ∆ T = 8 °C ∆ T = 2 4 °C ∆ T = 3 3 °C T ̃ 4 0 °C m stress Cyclical thermal -0.75 < ∆ L dyn < 0.75 mm stress -10 < σ < 10MPa (thanks to a 1.2 mm enforced 1.5 mm ‘dynamic’ thermal displ. [ ∆ L m =1.2 mm]) expansion enable by thin flange NBI 2003 - CNGS Horns Status 9 Presented by Sandry Wallon
2. Design & studies D y n a m i c s t u d y ⇒ fatigue strength axi-symmetric vibration mode 1 (140 Hz) movie Pt 1 (mode 1; 1+2) axi-symmetric vibration mode 2 Pt 3 (mode 1+2) (360 Hz) movie Pt 2 (mode 2; 1+2) σ ecr = 54 MPa (mode 2) [1] [1] : From Marek Kozien’s Ansys NBI 2003 - CNGS Horns Status 10 Presented by Sandry Wallon mode 1, mode 2, mode 4 study (Cern / Cracow university)
2. Design & studies F a t i g u e s t r e n g t h Warning Infinite lifetime do not exist! thermal + mechanical stresses : we are below the envelope curve NBI 2003 - CNGS Horns Status 11 fatigue-corrosion, SN curve 6082 Presented by Sandry Wallon
3. Manufacture & checkings Large parts Status Horns 1 et 1b : done Reflector : done outer conductor electrical connection NBI 2003 - CNGS Horns Status 12 Presented by Sandry Wallon
3. Manufacture & checkings Inner conductors Production status Horns 1 & 1b : done Reflector : in progress Rigid flange checking (large) Electrons Beam welding machine 2 inner conductors after EB welding NBI 2003 - CNGS Horns Status 13 Presented by Sandry Wallon
3. Manufacture & checkings Shot penning inner conductors Horn flanges’ checkings (after machining) → Ultrasonic → X ray → geometrical Horn inner conductors’ checkings (after welding) → X ray (for welds) Horn tronconical parts’ checkings (after machining) Reflector : cheaper processes used → Dye penetrant • rolled & welded sheet • TIG welding Status • dye penetrant (welds) Horns 1 & 1b : done • 3D checking Reflector : production in progress NBI 2003 - CNGS Horns Status 14 2 inner conductors after EB welding Presented by Sandry Wallon
3. Manufacture & checkings Inner conductor (final) checking Spec required : 1 mm shape tolerance Outer surface axis checking (straightness) clamp flanges 8 m long ‘bench’ intermediate supports NBI 2003 - CNGS Horns Status 15 Presented by Sandry Wallon
3. Manufacture & checkings Inner conductor (final) checking (as done) outer surface axis checking (straightness) Status Done Job done at Cern by • Ahmed Cherif (3D machine) • Dominique Missiaen (laser tracker) NBI 2003 - CNGS Horns Status 16 Presented by Sandry Wallon
4. Mounting & adjustements Horn’s mounting BAD surprise There’s a inner cond. non-conformity 2 sets of grooves are uncorrectly located NBI 2003 - CNGS Horns Status 17 Presented by Sandry Wallon
4. Mounting & adjustements Horn’s inner cond. non-conformity Actions Status → Crisis meeting! Done → Solution proposals → 3D design & drawing jobs → Mini prod. readiness review → Electrical insulators order → New spider manufacture → Outer conductor machining (new spiders locations) ⇒ Σ = 2.5 months → Find where do the mistake come from? ⇒ CAD (design) used as CAD (drafting) Other gift : Inner cond was designed with Euclid CAD soft, other parts and assemblies with Catia CAD soft! NBI 2003 - CNGS Horns Status 18 Presented by Sandry Wallon
4. Mounting & adjustements Inner conductor straightness adjustment Warning Former picture To be refreshed 1. Put a self centering probe inside inner conductor 2. Check probe position 3. Adjust wires tensile force until to find correct alignment 4. repeat previous job for 2 others cables sets Status Will be performed at (by) Cern within 2004 NBI 2003 - CNGS Horns Status 19 Presented by Sandry Wallon
4. Mounting & adjustements Centering stems & electrical connection adjustments Warning Former picture To be refreshed How to achieve interchangeability between horn and spare horn? Centering stems : position adjustment / inner conductor axis Electrical connection : position adjustment / inner conductor axis NBI 2003 - CNGS Horns Status 20 Presented by Sandry Wallon
4. Mounting & adjustements Horn axis adjustment Warning Former picture To be refreshed 2. Tighten / loosen 2 M12 screws (bottom screws) ⇒ vertical displ. ± 20 mm (top screws) ⇒ lateral displ. ± 20 mm 1. Loosen FCS / open strip lines / Unplug strip lines NB connection plates to be machined NBI 2003 - CNGS Horns Status 21 Presented by Sandry Wallon
5. Summary Horn manufacture : done, except FCS (production review within 1 month) Reflector manufacture : done, except inner conductor (to be deliver within january 2004) Non-conformity trouble : solved Adjustable support : jack received, other parts to be manufactured FCS & Striplines : design to be completed (production review within 1 month) Cooling system : ready for production review? Mechanical tests in progress (S. Rangod, G. Maire) : picture Electrical tests (horns, reflector, FCS) within 2004 NBI 2003 - CNGS Horns Status 22 Presented by Sandry Wallon
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