Date post: | 27-Dec-2015 |
Category: |
Documents |
Upload: | stewart-baker |
View: | 221 times |
Download: | 0 times |
Eucard WP 7.3 HFM
i r f u
yalcas
i r f u
yalcas
Winding and tooling tests
Insulation choice
F.Rondeaux
120-21 /01/2011 Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux
Eucard WP 7.3 HFM
i r f u
yalcas
i r f u
yalcas
Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux 2
Outline
• Tests :– First winding tests (March – April 2010)– Winding tests still to be done– Mechanical tests on stacks– Conductor behaviour during heat treatment
• Insulation– Specifications– Conductor insulation
20-21 /01/2011
Eucard WP 7.3 HFM
i r f u
yalcas
i r f u
yalcas
Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux
Tests
3
Coil design
Tests
Tooling design - Winding- Heat treatment- Impregnation
There is a list of questions we have to answer to be able to built the coil.The aim of the test program is to allow us to have these answers.
Validation of parameters- Materials parameters- Insulation thickness- …
Verify feasibility Winding tests
Geometry, dimensions of the moulds…?
20-21 /01/2011
Eucard WP 7.3 HFM
i r f u
yalcas
i r f u
yalcas
4Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux
First winding tests (March – April 2010) 1/4
• Q: how to wind the coil in the block design configuration(cf. II-4) with the design cable (cf.II-2)?
• Q: what geometry for the ends?
bending tests have been performed :
• bare copper cable • HFM dimensions • up to 10 turns.
• dedicated tooling with modularity • variable ramp angle • versatile HW-bend geometry • 3 options for the end
20-21 /01/2011
Eucard WP 7.3 HFM
i r f u
yalcas
i r f u
yalcas
5Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux
First winding tests – tooling 2/4
20-21 /01/2011
Eucard WP 7.3 HFM
i r f u
yalcas
i r f u
yalcas
Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux
First bending tests – results 3/4
• A tension of 30 daN has been considered as the best compromise in terms of cable behavior.
• The circular end (which shows simplest geometry and saves conductor in comparison with ellipse and superellipse end options) is retained.
6
Close‐up on the hard‐way bend zone after several turns
Bending test tooling (final configuration)
20-21 /01/2011
Eucard WP 7.3 HFM
i r f u
yalcas
i r f u
yalcas
Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux
First winding tests – results 4/4
7
• The flared configuration has been shown to be possible with the angle of 25° (considered as the largest reasonable value, and also the most critical in terms of bending radius): the cable is mechanically stable and a good quality winding has been achieved.
•Additional tests with other parameters (angle = 15°, opposite winding direction) have confirmed the result.
Profile obtained with the natural curvature of the cable (positions of the rolls)
R = 500 mm
20-21 /01/2011
Eucard WP 7.3 HFM
i r f u
yalcas
i r f u
yalcas
8Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux
Winding tests still to be done• Winding test with returned ends (dummy cable)
– Coil self supported– OK for the 2nd layer– Simplify the tooling – Avoid friction tape / rolls
• Validation of the winding options with the actual insulated cable.
20-21 /01/2011
Eucard WP 7.3 HFM
i r f u
yalcas
i r f u
yalcas
Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux
Mechanical tests on stacks
• Q: validate the hypothesis on properties of the materials used for the model.
• Q: define the size to be imposed on the coil during the heat treatment and the impregnation.
• Avoid over stress during the manufacturing steps.• Dimensioning the sections of reaction mould / impregnation mould.• Dimensions used in modeling (at low temp. under stress) ↔ dimensions
required for tooling.
• Tests on stacks – Modularity of the test setup (≠ heights, …)– Compression at 300 K, at 4K– Thermal restraint
920-21 /01/2011
Eucard WP 7.3 HFM
i r f u
yalcas
i r f u
yalcas
Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux
Conductor behavior during heat treatment 1/2
• Q : How to manage the behavior of the cable during the heat treatment?
- Stress relief, increase of volume during the Nb3Sn formation, thermal expansion...
- Influence of manufacturing process, composition and structure of filaments and strands
Tests to be performed on the 2 types of conductor (PIT, IT)
• How can we observe / quantify the deformation?
– Structure of the mould? Ends fixed?– Compression on the cable?
Need to define the experimental protocol
1020-21 /01/2011
Eucard WP 7.3 HFM
i r f u
yalcas
i r f u
yalcas
11Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux
Conductor behavior during heat treatment 2/2
20-21 /01/2011
• Potential configurations for heat treatment tests on cable :– Length of cable free (1 m)– Length of cable in a mould with ≠ fixation points– Length of cable following the end geometry + half of the strait section– …?
– Final test : full scale mock-up with 5 insulated turns
Eucard WP 7.3 HFM
i r f u
yalcas
i r f u
yalcas
Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux
Insulation• Based on NED developments. • Mechanical requirements : support 150 MPa in compression.• Electrical requirements : maximum service voltage = 1000V
Dielectric tests on the chosen materials• Thermal properties and radiation resistance are not an issue for FRESCA II
coil.
• Specifications (conductor insulation):– Insulation thickness : 150-200 µm per conductor face
• Q: How to qualify/verify the thickness of tapes?– Insulation type : S-glass fiber + epoxy resin
• Need of– Insulation between layers
compatibility with impregnation process requirement– ground insulation
1220-21 /01/2011
Eucard WP 7.3 HFM
i r f u
yalcas
i r f u
yalcas
13Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux
Conductor insulation• Insulation type : glass fiber + epoxy resin
– S2 glass tape desized• Tape (#416 from JPS) currently used for the SMC not completely
satisfactory.• Hiltex S2 tape used at CEA no more available.
Find new solution– Sleeve from Berkeley? – Braid S-glass tape directly on the conductor?
• RAL will check if it is possible– New tape (S2, Hiltex ALF boron free alumina-silica fiber tape …)?
– Vacuum impregnation • with epoxy resin (RAL, LARP …) ?
(baseline = RAL#71A , 100 p. DGEBA MY750 + 55p. POPDA HY5922, Hunstman)
• with cyanate ester / epoxy blend (chosen by ITER for radiation hardness) ?
• Insulation and impregnation will be tested on an SMC.
20-21 /01/2011
Eucard WP 7.3 HFM
i r f u
yalcas
i r f u
yalcas
14Dipole design review- II-8 Winding and tooling tests – insulation choice – F.Rondeaux
Conclusion
• Good quality winding can be achieved in the design geometry.
• Next steps:- Winding test with returned ends (dummy cable + actual insulated
cable): tooling under study.
- Mechanical tests on stacks : to be defined.
− validate the parameters used for the design studies
− dimension the moulds
- Management of the conductor behavior of the conductor during the heat treatment: study starting.
- Choice of the insulation : search of solution under way.
• The detailed program is under construction.
Thanks for your attention
20-21 /01/2011