LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 06 June 2006 No 1 /17 LARP Phase II Secondary...

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 06 June 2006 No 1 /17

LARP Phase II Secondary Collimator RC1

Collimator Test Program Plan Forward

Revised 6/21/06


Jaw/Cooling Tube Joint Development

Winding test piece 200mm long x 86mm diameter



Section view of test piece brazed with Jaw sections

200mm

136mm dia


Jaw/Mandrel/Cooling Tube R&D Plan

Square Tube drawn into mandrel groove

Tack weld coil to mandrelduring winding to prevent

spring back

Braze assembly together

Machine od to eliminate distortions & add wire groove

Braze togetherwith Jaw halves

(wire & foil)

Fabricate Copper Mandrel

Cut into sections forbraze joint inspection

Document results withphotos and write-up of process


Single Jaw Thermal Test Hardware

– Long lead items (2-6 weeks)• 2x Heater controllers are on order… due now

• Ready to buy 4x 5kW electric resistance heaters (380 mm long)

• Ready to buy Glidcop for 1 Jaw

• Ready to buy Glidcop for 1 Mandrel

– Jaw to be bored for heater• Bore to be .05 mm dia oversize of actual heater size (15.88 mm dia)

– Thermocouple attachments in Jaw• Locations, depth, size, electrical isolation features in Jaw TBD

– Jaw Support( bearings and mount)• RC1 Bearings

• Mount them on “V” blocks or simple fixed supports

– Rigid mounting for capacitance sensors• Locate at ends and center of Jaw



– Instrumentation is on order and is due early July:

• 1 each SCXI-1600 USB Data Acquisition and Control Module• 1 each SCXI-1001 12-Slot Chassis U.S. 120 VAC • 1 each SCXI-1303 32-Channel Isothermal Terminal Block• 1 each SCXI-1102B 32-Channel Amplifier, 200 Hz Bandwidth• 12 each SCXI-1361 Rear Filler Panel• 8 each SCXI-1360 Front Filler Panel Cover• 1 each Shielded Cable for interconnect• Cost is about $4700

– Project has PC with Labview software installed and an experienced LabView operator



Model of Cooling Coil on Mandrel



Rotational torque is reduced from previous design

Cross-section of Supply and Return Lines



Jaw Sections

~450 mm long Jaw sections are manufactured as half cylinders for assembly ease and the best braze possible


Single Jaw Test Thermocouple Locations

•Thermocouples are recessed into Jaw slightly below the surface

•Spaced along Heater length and equally spaced half way around Jaw circumference

•Should yield the Jaw heating profile predicted by the FE analysis

16 x Thermocouples

2 x 5kW Heaters



Test Lab Setup Block Diagram

PC with LabViewSoftware

Heater #1 Controller

Heater #2 Controller

Capacitec Signal Amplifier

DAC & Signal ProcessorJaw thermocouples

Jaw deflectionsensors

Jaw Heater #1

Jaw Heater #2

Over Temperature Control

Jaw Internal Cooling

Line

Chiller

LCW Water (Supply)

LCW Water (Return)

fuse

fuse

fuse

fuse

Bldg Power

Bldg Power

100 Amp Tap


RC1 Prototype Project Plan

Thermal Test and RC1 Mech Design Schedule from June 6,2006 forward



– Square tubing/grooved mandrel• Simplified process overview :

– UHV clean mandrel and anneal tubing prior to winding

– Wind the cooling tube onto the mandrel in a “clean room”

– TIG tack weld coil to mandrel during winding

– QA assembly prior to brazing with “ball test” of completed Mandrel assembly (60% diameter spherical bead)

– Braze coil to mandrel

– Machine Coil/Mandrel to remove distortions & add braze wire groove

– Braze Jaw sections to Coil/Mandrel Assy

– Machine external surfaces of Jaw to finished shape


RC1 Mechanical Prototype Test

Purpose: bench top testing of the jaw actuating mechanism in CERN orientations

– Vacuum tank with easy access– CERN adjustment mechanism– SLAC cooling water feed-throughs and flexible connections – SLAC rotation mechanism– Simplistic control system for jaw aperture– Minimal instrumentation connections for position, temperature, etc. – RC2 will incorporate LHC-compliant interfaces– Heat loading may not be possible – Use CERN Phase I components as appropriate


Development/Test Lab Layout

Item availability

Chiller & LCW existing

Vacuum equip’t SLAC misc?

Heater controller On order

Gantry existing

Tools, table existing

Instrumentation Ready to buy

Power panel, etc. to be installed


RC1 Mechanical Prototype

FY08, RC2

FY07

RC1 consists of jaws, tank & actuators - evaluated for horizontal (shown), vertical (90o) and skew (+/- 45o) orientations.

Variant: use CERN vac tank, dummy jaws of correct weight

LARP LHC PHASE II COLL RC1 TESTS - S. Lundgren 06 June 2006 No 1 /17 LARP Phase II Secondary...

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