MQXFB design, assembly plans & tooling at CERN

J.C Perez

On behalf of MQXF collaboration team

MQXF Workshop on Structure, Alignment and Electrical QACERN

2-4 February 2016

OUTLINE

MQXFB magnet design MQXFB assembly plans and tooling at CERN Conclusions

February 2-4th 2016J.C. Perez MQXF Workshop at CERN 3

Special thanks to Bruno Favrat for his contribution to this presentation !

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MQXFB magnet design

February 2-4th 2016J.C. Perez MQXF Workshop at CERN

• ≈7.5 meters long coils• 50 mm thick aluminum collars • Coil angular positioning w.r.t collars using radiation

resistant G10 alignment keys• Pads assembly : combining 5.8 mm and 28 mm pieces• ≈ 3.8 m long masters & bladders• Jokes assembly : using 5.8 mm and 46 mm thick pieces• 10 long and 2 short aluminum shells• ≈ 8.5 long rods for longitudinal loading• ≈ 10 meters long ½ SS shells to be welded

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¼ Yoke packs preparation

February 2-4th 2016J.C. Perez MQXF Workshop at CERN

• 5 modules of yoke + shells per magnet pre-assembled using bladders and yoke keys

• ¼ yokes assembly operation will be performed on horizontal position using temporary tie-rods

• 2 & 3 shells configuration to be assembled• 50 mm thick plates are required at shells junctions to bolt

the supporting blocks for backing strip welding (strips tack-welded to the blocks)

3 Shells configuration1 short & 2 long

1708 mm

2 Shells configuration1368 mm

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Yoke and Shell assembly

February 2-4th 2016J.C. Perez MQXF Workshop at CERN

• Assembly performed in vertical position and then pivoted• Bolting yokes against the shell throw shell windows may be considered

as an alternative solution for bladders operation (see Nicola’s presentation)

• Smaller yoke-keys will be used for safety • Temporary rods will be removed after yoke-keys insertion• Assembly procedure and comparative geometrical measurements to be

validated during MQXFSD3 mechanical structure assembly (Feb-2016)

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Yoke and Shell modules assembly

February 2-4th 2016J.C. Perez MQXF Workshop at CERN

• Each individual yoke pack will be measured during MQXFSD3 and prototypes assembly phase

• 2 mm gap to be guaranteed in between 2 adjacent yoke/shell sub-assembly (yoke longer by 1 mm at each extremity by design)

• Overall magnet length to be adapted? Can be done by machining the 2 SS end-plates

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Yoke & Shell modules assembly table

February 2-4th 2016J.C. Perez MQXF Workshop at CERN

• The horizontal alignment plane will be defined by the top surface of the pieces holding the 2 vertical ¼ yokes at each shell extremity

• 6 alignment fixtures equipped with cylindrical pins will ensure the lateral position of the yoke/shell sub-assemblies and guarantee the full assembly straightness over ≈7.5 m

Horizontal reference plane

Transversal alignment

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Yoke & Shell modules assembly(1/4)

February 2-4th 2016J.C. Perez MQXF Workshop at CERN

• 3 shells module will be placed on its support feet and blocked in longitudinal direction• The next module will be placed on top of its corresponding feet with a distance between 2

adjacent shells of ≈10mm

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Yoke & Shell modules assembly (2/4)

February 2-4th 2016J.C. Perez MQXF Workshop at CERN

10 mm

ContactSee next

slide

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Yoke & Shell modules (3/4)

February 2-4th 2016J.C. Perez MQXF Workshop at CERN

• Hydraulic cylinders (if required) and intermediate tie-rods will be used to pull and temporary clamp 2 modules together

• The contact between 2 sub-assemblies will be located on the faces of the thick extremity lamination plates

• Temporary tie-rods will be removed after compressing the modules

• No alignment pins will be used in between 2 modules (final magnet alignment provided by bladders operation when loading the coil-pack: to be confirmed during first prototype assembly)

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Yoke & Shell modules (4/4)

February 2-4th 2016J.C. Perez MQXF Workshop at CERN

• The same sequence will be repeated to assemble the 4 remaining modules using tie-rods adapted to the required length

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Load pads and aluminum collars assembly

February 2-4th 2016J.C. Perez MQXF Workshop at CERN

Stainless steel tube tack welded for thin laminations assembly

• The central part of load-pad packs will be assembled on top of a reference table using a SS tube (tack welded at the extremities)

• 50 mm SS pieces will be then assembled using 50 mm bushes

• Stainless steel rods will be used for longitudinal compression

• The aluminum collars will be assembled on top of the full length ¼ pad assembly using bushes

• Top part and pad indentation will be used as assembly reference plans for ¼ collar packs

• Stainless steel rods will compress the collar assembly

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7.5 meters

Coils assembly

February 2-4th 2016J.C. Perez MQXF Workshop at CERN

• 4coils ≈7.5 meters long to be assembled (How to support them over the full length?)

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Coil-pack assembly (1/2)

February 2-4th 2016J.C. Perez MQXF Workshop at CERN

• Assembly method as for MQXFS

• Upper ¼ pad & collars preparation

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Coil-pack assembly (2/2)

February 2-4th 2016J.C. Perez MQXF Workshop at CERN

• Aluminum collars will not be bolted• Bolting of the load-pads for coil pack assembly will be performed using screws

spaced by ≈350 mm • The new assembly procedure has been tested at CERN (using MQXFSD0 first

structure: thick laminations ) during MQXFSD2 assembly (3 shells configuration).• The same procedure will be applied on MQXFD3 mechanical structure assembly

(new laminated structure using a 3 aluminum shell configuration: see Nicola’s talk)

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Masters assembly

February 2-4th 2016J.C. Perez MQXF Workshop at CERN

• The masters will be bolted to the pivoting supports for assembly operation• Temporary removable clamps will be placed around the coil-pack and masters to

guarantee their correct positioning during insertion operation

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Coil-pack insertion

February 2-4th 2016J.C. Perez MQXF Workshop at CERN

• The same insertion table concept used for MQXFS assembly will be scaled-up for MQXFB coil-pack insertion

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Coil-pack insertion

February 2-4th 2016J.C. Perez MQXF Workshop at CERN

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Longitudinal compression and connection box

February 2-4th 2016J.C. Perez MQXF Workshop at CERN

The connection box will be mounted after shell

welding operation

End-plate assembly and axial loading using the system validated on MQXFS

Conclusions• MQXFS assembly procedure has been defined and is being tested during MQXFS

model program • The assembly procedure will be extrapolated for MQXFB construction and validated

on the first prototype to be built at CERN from February 2016 on• Most of the existing tooling can be scaled-up from models to 8 m long magnet• Structure components detailed design to be completed by summer 2016• First MQXFB prototype (mirror configuration) assembly scheduled for Q1-2017• Handling and assembly tooling to be designed and manufactured• No show-stopper identified so far

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The HiLumi LHC Design Study is included in the High Luminosity LHC project and is partly funded by the European Commission within the Framework Programme 7 Capacities Specific Programme, Grant Agreement 284404.

Thank you for your attention