Progress on the MICE Coupling Solenoid Magnet

-1-Oct. 07-10, 2007, MICE- CM19 ICST/HIT

Progress on MICE Coupling Solenoid Magnet

ProgressProgress

on theon the

MICE Coupling Solenoid MagnetMICE Coupling Solenoid Magnet

October 8, 2007October 8, 2007

Institute of Cryogenics and Superconductivity TechnologyInstitute of Cryogenics and Superconductivity Technology

Harbin Institute of Technology, China Harbin Institute of Technology, China

-2-Oct. 07-10, 2007, MICE-CM19 ICST/HIT


Progress• The inner coil radius was changed from 744 mm to 750 mm to allow

more space between the coil inner side and the inner vacuum chamber.

The engineering design was updated accordingly.

• The coil winding system is under construction with the funds from HIT.

• The prototype coils were designed.

• The formal collaboration MOU between LBNL & HIT was developed and

signed by both last June. The formal Addendum to the MOU between

LBNL and HIT, and the Technical Agreement for the MICE/MUCOOL

coupling magnets was developed and signed in September.

• The formal proposal for MICE project to the Ministry of Science and

Technology of China was submitted by HIT at the end of this June with

SOA and MOU from MICE collaboration and LBNL.



Stress analyses on the vacuum vessel and cold mass supports were completed.

Improvement on quench protection programming with quench back, and optimization of the quench protection circuit design are underway.

The fabrication plan (e.g. winding procedure and tooling, and assembly procedure and tooling etc.) is further detailed.

For coil assembly, study on effects of coil winding tension, banding applied to the outer surface of the coil and the possible inclusion of slip planes at the insulation interfaces to the mandrel are being carried out. 2-D simulations on effects of slip planes at the insulation interfaces to the mandrel in the coil assembly were completed. 3-D simulations on effects of coil winding tension and banding applied to the outer surface of the coil is almost done.

Test for thermal properties of AIN and contact resistance among AIN, indium film and cooler cold head by PTR-407 in ICST is under way. The test station was designed, built and under commissioning.

• The engineering design on the coupling magnet has been further updated

and detailed.



Updated Design

• Basic design parameters for the coupling coil

• Main structure design parameters

• Heat loads

• Magnetic fields on coupling coil

• Effect of stray fields on HTS leads and cryocoolers

• Magnetic forces on coupling coil

• Passive Quench protection design

• Winding system design and construction

• Prototype coils’ design

• Vacuum chamber design



Basic Design Parameters of the Coupling Coil at p=200MeV/c

744mm IR coil 750mm IR coil

Parameter Non-flip Flip Non-flip Flip

Coil Length (mm) 285 285 285 285

Coil Inner Radius (mm) 744 744 750 750

Coil Thickness (mm) 102.5 102.5 102.5 102.5

Number of Layers 96 96 96 96

No. Turns per Layer 166 166 166 166

Magnet J (A mm-2)* 90.11 95.53 90.11 95.53

Magnet Current (A)* 165.2 175.1 165.2 175.1

Magnet Self Inductance (H) ~564 ~564 ~592.55 ~592.5

Peak Induction in Coil (T)* 5.85 6.20 5.842 6.194

Magnet Stored Energy (MJ)** ~7.7 ~8.6 ~8.08 ~9.085

4.2 K Temp. Margin (K)* ~1.8 ~1.6 ~1.867 ~1.693

4.2 K Temp. Margin (K) at worse case ~1.1 ~0.8 ~1.1 ~0.792

Length of conductors per coil (km)

~79.585 ~ 80.188



Main structure design parameters


Inner radius of inner vacuum shell (mm) 694.4 694.4

Length of vacuum chamber (mm) 489 489

Thickness of inner vacuum shell (mm) 3.5~4.0 3.5~4.0

Thickness of heat shield (mm) 1~2 1~2

Inner radius of coil (mm) 744 750

G-10 insulations for coil-to-ground (mm) 0.5x2 0.5x2

Insulations between coil and end plates (mm) 3.5 3.5

Thickness of coil (mm) 102.5 102.5

Length of coil (mm) 285 285

Layers of coil 96 96

Turns per layer 166 166

Thickness of coil bobbin (mm) 13 13

Thickness of coil end plates (mm) 19 19

Thickness of cover plate (mm) 15 16

Thickness of banding (mm) 20 13




G-10 insulations between coil and banding (mm) 1.0 1.0

Space between 4.2K and heat shield (mm) 9.7 15

Space between heat shield and 300K (mm) 18 18

Fig. Cross-section of the cold mass for a coupling coil with 750mm inner radius



Comparisons

The self inductance of the coil increases from 564 H to 593 H (~5%) ,

and the magnet stored energy increases about 4% with the coil inner

radius increasing from 744 mm to 750 mm.

The peak induction in the coil and the temperature margin dropped by

a small amount.

The space between the cold mass and the inner thermal shield

increased from 9.7 mm to 15 mm, which will be helpful in reducing the

heat load at 4.2K.



FEA results on stress and deflection of the coil assembly

Total deflections [m]



Von Mises stress [Pa]



Shear stress in the RZ cross-section of coupling magnet (Pa)



FEA results on temperature distributions for the coil assembly

ΔT between the hot spot on the 750mm IR coil inner surface (at the high field region) and the inner surface of the helium tubes is 0.082K (less than 0.1K) at state steady operation for four cooling tubes in parallel (26x2).



744mm IR coil

Time (s) Hysteretic Loss (W) Mandrel Loss (W)* AC Loss (W) ΔT(K)

1733 1.68 0.05 1.73 0.250

5198 0.94 0.05 0.99 0.165

8663 0.61 0.05 0.66 0.128

12127 0.46 0.05 0.51 0.112

ΔT and AC loss with time during charging process

750mm IR coil

Time (s) Hysteretic Loss (W) Mandrel Loss (W) AC Loss (W) ΔT(K)

1733 1.63 0.068 1.698 0.225

5198 0.93 0.068 1.001 0.14

8663 0.61 0.068 0.678 0.1

12127 0.46 0.068 0.528 0.082

*AC loss in banding is not included. A normal charge time is 13860 seconds (based on a charge at the full voltage delivered by the power supply) .



744mm IR coil

Time (s) Hysteretic Loss (W)

Mandrel Loss (W)* AC Loss (W) ΔT(K)

450 1.75 0.74 2.49 0.287

1350 2.34 0.74 3.08 0.353

2250 3.62 0.74 4.36 0.494

3150 6.48 0.74 7.22 0.798

ΔT and AC loss with time during fast discharging process

750mm IR coil

Time (s) Hysteretic Loss (W) Mandrel Loss (W) AC Loss (W) ΔT(K)

450 1.78 1.02 2.80 0.221

1350 2.37 1.02 3.39 0.292

2250 3.62 1.02 4.64 0.438

3150 6.32 1.02 7.34 0.739

*AC loss in banding is not included. A rapid discharge has a time constant of 3600 seconds (based on a peak voltage across the coil of 33.6 V when a resistance of 0.16 ohms is put across the coil at the power supply).



Comments

The thermal stress still dominates as compared to the magnetic coil forces

During cool down from 300K to 4.2K, the coil center moves inward about 2.9 mm.

When powered to 210 A, the coil center moves outward about 0.9 mm

Most stress in the coil is less than 40 MPa due to thermal contraction and increases

when powered. The peak stress is about 94 MPa in the corners and where the peak

field is located

The maximum stress due to cool down in the Al coil case is at the corners (92 MPa)

and increases to 142 MPa when powered, which is less than the allowable stress of

6061T6 Al at 4.2K (~161 MPa)

The hot spot appears at the high field point in the coil winding for normal operation,

and the ΔT of 0.082K is acceptable

Due to the reduced thickness of Al banding, the ΔT between the hot spot in the coil

and the cooling helium decreases (even though the AC losses increase for the larger

diameter coil)

The stress & deflection in the coil and the AC losses changed only slightly.



Heat load (W) 750mm IR coil 744mm IR coil

Copper leads 19.30 19.30

60K cold mass supports 3.0 3.0

Radiation heat to 60K thermal shields

8.54 8.5

60K Intercepts for instrumentation wires

1.0 1.0

60K intercepts for neck tubes

6.0 6.0

Heat shield supports 1.0 1.0

Sub-total 38.84 38.8

Contingence 30% 30%

Total 50.49 50.44

Heat loads at 60K

Cryomech PTR415, 55W/60K for the 1st-stage, 1.5W/4.2K, 50Hz for the 2nd- stage; with a remote valve motor, at least 10% deduction to 1.35W/4.2K.



Heat loads at 4.2K*

Heat load (W) 750mm IR coil 744mm IR coil

HTS current leads 0.13 0.13

4.2K Cold mass supports 0.20 0.20

Radiation heat to 4.2K cold mass 0.71 0.7

4.2K Instrumentation wires 0.12 0.12

4.2K neck tubes 0.14 0.14

Superconducting joints 0.012 0.012

Sub-total 1.312 1.302

Contingence 30% 30%

Total 1.71 1.69

* The heat load for the IR744 is only different from the IR750 coil in the radiation heat load.



Pro/E drawing by C.S.Liu

MICE Coupling magnet engineering design

Al coil mandrel

G-10 insulation

Coil

Al banding

Cover plate

Cooling circuit

Cold mass supports

Cryocoolers

Heat shields

Vacuum chamber

He collection box

LHe distribution container

He condenser



Cryocoolers

Power leads

Cold mass supports

Coil assembly

He cooling pipes

Thermal shields and intercepts

Vacuum vessel He condenser

Pro/E drawing by C.S.Liu



Magnetic Field around Coupling Coil at Flip Mode

200MeV/c (T) 240MeV/c (T)

Magnetic fields on coupling coil



Magnetic Field around Coupling Coil at Solenoid Mode

200MeV/c (T) 240MeV/c (T)



Fig. 3-1-1 Magnetic field on the axis of MICE cooling channel at flip mode

2.613T

2.176TCoupling coils



Fig. 3-1-2 Magnetic field on the axis of MICE cooling channel at solenoid mode

Coupling Coils

2.634T

2.197T

Coupling Coils



Effect of Stray Magnetic Field on HTS Leads

R=1458mm, Z=-164mm, B=0.313T (0.310T)

B [T] only considering Coupling Coil B [T] in MICE channel



Effect of stray magnetic field on cooler drive motor

B (T) only considering coupling coil B (T) in MICE channel

R=1.74m, Z=0.05m, t=±0.11m



Comments

The maximum field on the coupling coil is 7.40T for the 240MeV/c

flip mode (7.44T for 744mm IR coil), which is on the inner surface

of the coil.

The influence of magnetic field on the coupling coil from other

coils in the channel is not much (within 2 percent).

The effects of stray magnetic fields on the HTS leads and

cryocoolers are nearly unchanged for the 750 mm coil design

compared with the 744 mm coil.



Longitudinal magnetic forces on coupling magnet

Case RFCC1 RFCC2

Flip200Mev/C 170.7 170.7

240Mev/C 253.2 253.2

Non-Flip200Mev/C -160.4 -160.4

240Mev/C -237.3 -237.3

When all coils in the MICE channel operate normally (kN)

When various coil circuits quench at 240MeV/c (kN)

All Focus magnets normal

One detector magnet normal

Both detector magnets normal

RFCC1 normal

RFCC2 normal

Non-flip

RFCC1 -228.3 -312.6 -307.1 0 60.6

RFCC2 -228.2 -231.7 -307.1 60.6 0

Flip RFCC1 249.7 332.2 338.1 0 -81.6

RFCC2 249.8 259.1 338.1 -81.6 0



Note: Negative force is toward the channel center, and positive force is away from the channel center.

When current leads are reversed in 240MeV/c flip mode (kN)

Module RFCC1 RFCC2

AFC Reversed 246.3 246.3

Coil C1 Reversed -253.5 -416.4

Coil C1 and Coil C1 Reversed 461.1 416.2

Coil M1 Reversed 331.1 331.2

Coil M2 Reversed 281.4 281.5

Spectrometer Reversed 316.0 316.0

• The maximum magnetic force on the coupling coil is 416.4 kN (399.4 kN for 744mm IR coil), towards the channel center.

• The design longitudinal load for the cold mass supports is assumed to be 500kN (including some contingency).

• The cold mass support design is the same as that for the 744 mm coil.



Calculation Results for Rp=5Ω


w/Quench back

w/o Quench back

w/Quench back

w/o Quench back

4-section

Hot Spot temperature (K) 107 150 108 150

Max Internal Voltage (V) 3818 3834 3868 3888

Max Layer-to-Layer Voltage (V) 318 320 322 324

6-section




8-section




Passive Quench protection system

Due to increased self-inductance and magnet stored energy, the maximum internal voltage during quench is higher for the new design.



Winding system design & construction

The coil winding system design based on a wet winding process using filled epoxy is essentially complete. Safety interlocks will prevent overtensioning or breakage. A conductor guidance system has been designed.

spool

Tension feedback

Winding machine

Automatic guider

Dereeler (an unwinding facility)



Spider support for coil winding

The winding pre-tension is set at ~100MPa.



Winding Hall

水池

衣柜

线轴

电源

气源

电源电源

电源

配电柜

鞋柜

吹淋A

B

换鞋柜

吸尘器

拉门

拉门

吹淋室更衣室

洁净间

送风口

送风口

Drawing by Liu ShouYin

1. Winding System2. Soldering tooling3. Movable crone4. Work bench5. Window



Schematic of Control System

PLC

M~

Main Shaft

GuiderTension

Regulation

Dereeler

PG M~PG Position

SensorM~

VFC Driver

PC

VFC

Conversion



Function of the Control System

Switch between automatic and manual

Switch between forward and reverse rotation

Stop at anytime by one key or button

All motors are of power-failure brake type

The tension system can stably operate in the range of 5 to 50kg

Wire length will be auto-counted

The status of each component is monitored

The HMI is not finished; a historical table and background database will be added



Winding Machine



Guider Locating Platform



Design of prototype coils

Coil Parameters

ID (mm)

OD(mm)

Average D (mm)

Coil Length(mm)

Thickness (mm)

Layers Turnsper

layer

coil I 350 401 375.5 285 25.5 24 166

coil II 1500 1704 1602 72 102 96 42

Coil I: small coil; Coil II: prototype coil



Small coil

•It is proposed that a small superconducting coil be wound using about 5

km of tracker solenoid conductor

•This coil winding would be used to test and debug the winding machine

and the wire tensioning device

•The small test coil will demonstrate: fabrication of coil splices during

winding, the wet winding process, conductor connections for coil voltage

taps and the quench protection system

•The test coil will be high potted to a voltage that is higher than that

required for the coupling solenoid (>5 kV)

•The coil can be run in liquid helium at ICST



Parameter Value

Coil Length (mm) 285

Coil Inner Radius (mm) 175

Coil Thickness (mm) 25.5

Number of Layers 24

No. Turns per Layer 166

Magnet J (A mm-2) 114.6

Magnet Current (A) 210

Magnet Self Inductance (H) 4.484

Peak Induction in Coil (T) 2.788

Magnet Stored Energy (KJ) 99.867

Parameter Value

Inner radius of coil (mm) 175

Thickness of coil (mm) 25.5

Length of coil (mm) 285

Layers of coil 24

Turns per layer 166

G-10 insulations for coil-to-ground (mm)

1.0

Insulations between coil and end plates (mm)

3.5

Thickness of coil bobbin (mm) 8

Thickness of coil end plates (mm) 8

Thickness of cover plate (mm) 5

Thickness of banding (mm) 5

Basic design parameters for small coil Main structure design parameters



2853

825.5

55

1

3 8

0.5

0.5

8

350

401



The coil can be charged up to 500A using two 300A power supplies in parallel

Load line for small coil



Prototype Coil

• Wind a full diameter test coil (prototype coil) with ~20 km of

conductor to demonstrate the highest field and strain state of the

coupling magnet in the MICE cooling channel

• The purpose of the prototype coil is to test the coil under strain

conditions that are greater than would be encountered in the

coupling coil. Training can be done if needed.

• The coil would be mounted in an ICST vacuum vessel. The magnet

would be cooled using the ICST refrigerator.



Parameter Value

Coil Length (mm) 72

Coil Inner Radius (mm) 750

Coil Thickness (mm) 102

Number of Layers 96

No. Turns per Layer 42

Magnet J (A mm-2) 114.6

Magnet Current (A) 210

Magnet Self Inductance (H) 50.059

Peak Induction in Coil (T) 3.906

Magnet Stored Energy (MJ) 1.104

Parameter Value

Inner radius of coil (mm) 750

Thickness of coil (mm) 102

Length of coil (mm) 72

Layers of coil 96

Turns per layer 42

G-10 insulations for coil-to-ground (mm)

1.0

Insulations between coil and end plates (mm)

3.5

Thickness of coil bobbin (mm) 8

Thickness of coil end plates (mm) 8

Thickness of cover plate (mm) 5

Thickness of banding (mm) 5

Basic design parameters for Coil II Main structure design parameters



Coil

G-10

Bobbin

End Plate

Cover Plate

Banding72

5

5

1

8

3

8

3

8

0.5

0.5

102

1500

1704



Load line for prototype coil

The coil can be charged up to 400A using two 300A power supplies in parallel



Magnetic field in the prototype coil at 210A



Total deflections (m)

Coil ICoil IIDue to cooling and magnet force



Von Mises stress in the test coils at 210A

350 25.5×285 1500 102×72R

Z

Coil I Coil II



Comments for Coil I at 210A

The magnetic induction in the center of small coil is about 2.27T.

The peak magnetic induction on the small coil’s inner surface is about 2.8T

The maximum stress is in the banding (75.2 MPa), which is within the

strength limit of Al 6061-T6

With 2-sectioned and 0 resistor, the hot spot temperature is about 65K,

and the peak internal voltage is about 135V

Comments for Coil II at 210A

The magnetic induction in the center of prototype coil is about 0.65T

The peak magnetic induction in the coil’s inner surface is about 3.91T

The maximum stress is in the banding (93.9 MPa), which is within the

strength limit of Al 6061-T6

With 4-sectioned and 0 resistor, the hot spot temperature is about 65K,

and the peak internal voltage is about 135V



Von Mises stress in prototype coil at 400A

Prototype Coil Coupling Coil

Current (A) 400 210

Von Mise stress in coil (MPa) 115 93.4

Von Mise stress in mandrel (MPa) 154 142



Vacuum vessel designPTR coolers

Helium Bayonets

Reinforcement ribs

Vacuum port

Cold mass support

Bus-bar for leads



Parameters Unit

Overall height （ A1） 3076 mm

Height to remove coolers （ A2） 2885 mm

Overall width （ C） 1262 mm

OD 2160 mm

ID 1389 mm

Overall weight ≈2480 Kg

Coil weight ≈950 Kg

Overall parameters for vacuum vessel



Total deflection of vacuum vessel



The Von Mises Stress of vacuum vessel



Proposed Milestones

Milestone Description ResponsibleParty

Date

Complete and test two sample coils ICST 02/28/08

Complete winding of MuCool coil on mandrel ICST 04/30/08

Complete winding of 1st MICE coil ICST 08/07/08

Complete MuCool cold mass assembly and test ICST 06/23/08

Complete design of MuCool support stand ICST 06/13/08

Complete winding of 2nd MICE coil ICST 09/29/08

Complete 1st MICE cold mass assembly and test ICST 10/23/08

Install MuCool cold-mass supports, and assemble MuCool magnet cryostat and leak check

ICST 09/16/08

Complete 2nd MICE cold mass assembly and test ICST 11/20/08

Complete factory acceptance test for MuCool coil ICST, LBNL 10/10/08



Milestone Description ResponsibleParty

Date

Install 1st MICE cold-mass supports, and assemble 1st MICE magnet cryostat and leak check

ICST 12/31/08

Install 2nd MICE cold-mass supports, and assemble 2nd MICE magnet cryostat and leak check

ICST 01/31/09

Complete factory acceptance tests for 1st MICE coil ICST, LBNL 01/20/09

Complete factory acceptance tests for 2nd MICE coil ICST, LBNL 02/28/09

-57-Oct. 07-10, 2007, MICE- CM19 ICST/HIT


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Progress on the MICE Coupling Solenoid Magnet

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