Integrated “Super Modules ” + New Prototypes � Motivations � Motivations � Key features for Super Modules (SM) � Key features for Super Modules (SM) � CAD description and Material list (X 0 ) � CAD description and Material list (X 0 ) � Prototype program 2010-2011 � Prototype program 2010-2011 � Integration to the structures and FEA’s � Integration to the structures and FEA’s On behalf of the team @ University of Geneva: A.Clark, G.Barbier, F.Cadoux, D.Ferrère, S.Gonzalez-Sevilla, C.Husi, M.Weber And KEK : Y. Ikegami, S. Terada, Y. Unno CERN, AUW the 11th of Nov, 2010 1
Motivations [1] A. Viability was proven of the End insertion / 2 types (STAVE and Super Modules SM1.0) The key idea was to perform an OPTIMISATION on Super Module approach. Super Module Clamping point (version SM1.0) free along Z Module assembly v1 (prior Insertion) Z0 Z0 Z 1200 Z 1200 Module assembly v1 (prior Insertion) CERN, AUW the 11th of Nov, 2010 2
Motivations [2] STAVE Design acc. to Geneva concept (as shown in November 2009 with a demonstrator, see presentation: STAVE_Nov09UNIGE.ppt ) Module assembly v1 (prior Insertion) Locking mechanism at Z0 We widely benefited from our STAVE proto development… which led us to adapt some ideas on the Super Module “Optimized version” (SM2.0)… CERN, AUW the 11th of Nov, 2010 3
Motivations [3] B. Immediate goal: benefit from the “8 Modules assembly” used for testing ..and to make them compatibles on a light structure in a coherent way Multi-purpose jig: - Pipe and block assembly - Module mounting - Service mounting - Transport, storage and Tests CAD pictures taken up from Didier’s talk (thanks to Maarten Weber for all this detailed development) CERN, AUW the 11th of Nov, 2010 4
Key features on Super Modules Concept KEY POINTS KEY POINTS - Based on a modular concept (modules, cooling, local support, service bus, SMC,…) - Full module coverage in Z due to overlaps (shorter barrel structure) - Rework is a strong feature and can be done up to the commissioning - Good thermal performances (for both CO2 and C3F8… and the choice of coolant could be done late / design development!) - The sharing of work can be optimized and spread over several institutes: support, Modules, Cable bus, SMC...and testing at intermediate steps (Modules, SMC) - An easy handling due to the CFRP mechanical frame - And last but not least, it allows a free stress insertion for every position in Phi CERN, AUW the 11th of Nov, 2010 5
CAD description [1] Complete integrated CAD view of the SM2.0 (12 modules assembled thru the cooling block) Envelope for service bus and connections (still to be optimized) Service Module SMC at the end Z0 Z600 Z1200 From the end view… Enveloppe for service bus and connections Thanks to Gerard Barbier Link to structures for this optimization work CERN, AUW the 11th of Nov, 2010 6
CAD description [2] Assembly main steps (based on “8 modules” project) 1 …then, populated with cooling plates 2 Starting from a bare jig… 3 4 …1 out of 2 modules …assembly completed fixed to the cooling plate with the rest of modules (after stand rotation) CERN, AUW the 11th of Nov, 2010 7
CAD description [3] Complete integrated CAD view of the SM2.0 (12 modules assembled thru the cooling block) Possible link to service bus Connector or wire bonding Cooling pipe Central CFRP pipe CFRP Guiding pipes CERN, AUW the 11th of Nov, 2010 8
Material list summary Estimate of the X 0 number Weight [g] % X0 LS for 12 MODULES 200.882 0.45 Cable bus 60.348 0.31 module 518.64 1.82 2.58 Total 779.87 CERN, AUW the 11th of Nov, 2010 9
Prototype program 2010-2011 [1] Our goal is to: Our goal is to: Develop 2 full length prototypes Develop 2 full length prototypes What means to build jigs and frames for What means to build jigs and frames for assembly and part manufacturing (see next) assembly and part manufacturing (see next) - 1 for Testing (sagging, …) - 1 for Testing (sagging, …) - 1 for Module assembly and further optimizations - 1 for Module assembly and further optimizations Cooling Plates x6 (still to be prototyped) CFRP Backbone (key part!) Every sub part assembled with epoxy (need of several jig) Support (CFRP) CERN, AUW the 11th of Nov, 2010 10
Prototype program 2010-2011 [2] Cross beams processing (in Carbon Fiber) Cross beams processing (in Carbon Fiber) 1 3 2 First 2 proto received so far for lay up validation (2 plies wrt 3 plies) Mold in 2 parts used to apply the Bonding of 2 sub parts CF skins (T300) Next 20 parts in production @ Composite Design… CERN, AUW the 11th of Nov, 2010 11
Prototype program 2010-2011 [3] Cross beams processing (in Carbon Fiber) Cross beams processing (in Carbon Fiber) Re machining on CNC (use of jigs, clamps,…) ⇒ Cross beams cut to final shape Multi purpose jig ⇒ Assembly and Machining of Complete cross beam end parts in peek (equipped with end parts in Peek) CERN, AUW the 11th of Nov, 2010 12
Prototype program 2010-2011 [4] Assembly jig Assembly jig Grooves Jig made out of cast Bonding and centering aluminum (called “G25”) of different parts Jig received this week @ DPNC CERN, AUW the 11th of Nov, 2010 13
Prototype program 2010-2011 [5] Assembly jig Assembly jig Jig and cradles to provide precise positions, clamping for bonding CERN, AUW the 11th of Nov, 2010 14
Prototype program 2010-2011 [6] Assembly jig Assembly jig Centering parts (x3) for locking mechanism bonding Z0 Z600 Could also be used a stand for future mechanical load tests (beginning of 2011) Z1200 CERN, AUW the 11th of Nov, 2010 15
Prototype program 2010-2011 [7] Assembly jig Assembly jig Ready for future tests (2 carbon fiber structures foreseen early in 2011 ) C o o l i n g p l a t e s … s e e n e x t CERN, AUW the 11th of Nov, 2010 16
Prototype program 2010-2011 [8] Cooling plate in CC-2D (2800), as machined by the KEK workshop (as shown at the 2008 June review, by S. Terada ) Cove Ø2.5Pipe Cooling plate Cross section CERN, AUW the 11th of Nov, 2010 17
Integration to the structure and FEA’s [1] FEA’s on Super Module (stress and sagging / 3 loads: Vertical, 16° , horizontal) 1200mm 3 load cases considered 1G 1G 1G Z0 Z1200 Meshing Sandwich of Silicon wafer + TPG Different plies and orientation of M55J fiber have been studied for Back bone… the rest in QI lamina (T300). Total weight from FEA: 800 gr . CERN, AUW the 11th of Nov, 2010 18
Integration to the structure and FEA’s [2] FEA’s on Super Module (stress and sagging / 3 loads: Vertical, 16° , horizontal) 1G Load case Deflection Max Stress (Mpa) (micron) 16° 77 11 Vertical 12 80 Horizontal 11 10 Eigenvalue f1: 57 hz - Modal shape Carbon fiber Layup (M55J) Module material assembly CERN, AUW the 11th of Nov, 2010 19
Integration to the structure and FEA’s [3] FEA’ s Extrapolations to a longer SM …in case the Barrels will extend up to …?? Case 1: extension to 1600mm Case 2: extension to 1600mm + NEW BC’s 1600mm 1600mm Z0 « Z200 » BC’s inwards shifting (200mm) 1 G sagging / Vertical U z (micron) = 73 U z (micron)= 166 ! « Z200 » Middle BC Z0 CERN, AUW the 11th of Nov, 2010 20
Integration to the structure and FEA’s [4] End Insertion using a removable backbone The SM slides w/o stress into the structure (locking in 3 positions) Backbone CERN, AUW the 11th of Nov, 2010 21
Integration to the structure and FEA’s [5] No Module shown (for clarity). Locking points over the length (Qty: 3) Z0 Z600 Z1200 Sliding guides Reinforcing ring and single skin cylinder Z0 Z600 Z1200 CERN, AUW the 11th of Nov, 2010 22
Integration to the structure and FEA’s [6] End view on a few SM , for cylinders 1 and 2…, … Cable bus to be optimized 16° CERN, AUW the 11th of Nov, 2010 23
Integration to the structure and FEA’s [7] Overall sagging : 4x2 Interlinks clamped to the Outer cylinder CAD model Boundary Condition (the way it’s clamped to the Outer Cylinder) BC Deflection Max Details on reinforcing rings… Stress could be filled in with foam case (micron) (better rigidity) (Mpa) 4x2 203 30 3x2 300 48 2x2 1400! 127 Nota : the margin of safety on the mass is 20% Eigenvalue 8 Hz (axis mode) (due to SM overestimated). PIXEL is based on 300Kg (!) …to be reconsidered CERN, AUW the 11th of Nov, 2010 24
Conclusions / Outlooks beyond 2010 � The optimization work (thanks to CAD and confirmed by FEA’s) shows that the Super Module in term of X 0 still have some potential to improve: 2,58 % with proposed LS Competitive number with respect to stave concept � In parallel to the “8 modules” project, we will build 2 full scale prototype in CFRP of the Super Module by the end of 2010-beginning of 2011 . � Structural tests will be carried out on the prototypes along with thermo elastics tests (?) CERN, AUW the 11th of Nov, 2010 25
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