LARP Phase II Secondary Collimator RC1 Prototype Engineering Status 6/21/06

2006-06-21Coll Eng E Doyle 1/18

LARP Phase II Secondary Collimator RC1 Prototype Engineering Status

6/21/06

Jaw-hub-shaft concept - continued

Permanent deformation (elastic/plastic analysis)


Overview

• Review– Baseline jaw– Central stop Concept

• Discuss RC1 baseline deflection reference• Refine baseline

– Shorter pitch cooling helix– Solid core

• New jaw-hub-shaft concept• Eliminate central stop?• Plastic deformation


Collimator TCSM.A6L7 Cooling scheme Helical Axial (36o)

# channels 1 2 Diam (m) .008 .006 Velocity (m/s) 3 3

Cooling

Total flow (l/min) 9 10 SS Power (kW) 11.7 Beam heat Trans Power (kW) 58.5

Jaw peak 86.5 91.5 Cooling chan. peak 68.3 69.7

SS

Water out 36.0 36.1 Jaw peak 231 223 Cooling chan. peak 154 130

Temp (C )

Trans

Water out 43.6 47 SS 394 107 Deflection (um) 4 Trans 1216 778 SS 43 75 Eff. length (cm) 5 Trans 24 31

Exceeds Allowed Deflections

All temperature simulations based on 20C supply. For CERN 27C supply add 7 to all temperature results. CERN max water return temp 42C

Exceeds spec, or other possible problem as noted

Review: Baseline Jaw Performance (deflections referred to edge of jaw - Note this is not a realistic mounting possibility)

Baseline: hollow Cu, 25mm wall, helical cooling - 5cm pitch

VV


Two concepts for reducing deflection

• Central aperture stop

• Separate shaft and jaw


86C

Bending exceeds 25um spec => Compromise:

Central aperture stop controls deflection - causes jaw to deflect away from beam – Note: this is idealized stop

x=394 m

Spec: 25m

support

support

Steady State operation (End supports as modeled)

More realistic: shaft support

-Swelling toward beam

-Bending toward beam

Idealized Central Aperture Stop

-Swelling neutrallized

-Bending neutralized


Leaf springs allow jaw end motion up to 1mm away from beam

RC1 Concept as presented to reviewers: Flexible end supports with central aperture stop

Stop prevents thermal bowing of jaws from intruding on minimum gap

Local swelling not controlled


Real aperture stop allows some swelling

Stop hidden out of beam’s reach at 45o

Swelling not fully neutralized – note bulge of hot region between stop and aperture.

Peak temperature due to beam heating

StopV


Jaw-hub-shaft - Eliminate Central Stop?

1. Hub acts as a heat sink near peak temperature location, lowering peak temperature, reducing gradient and bending.

2. Both ends of jaw deflect away from beam. (Note: swelling component of deflection is not corrected - ~ the same as for stop @ 45o.)

3. Max deflection toward beam reduced if the shaft deflection can be minimized

4. Cooling coils embedded in I.D. of jaw.

shaft jawhub


Advances since RC1 Baseline

solid core more cooling


shaft end

deflection reference jaw edge shaft central stop central stopbaseline (25mm) 394 426 36 390refined baseline (25mm) - 238 24 214jaw-hub-shaft (25mm) - 100 48 52

baseline (25mm) 1216 1260 97 1163refined baseline (25mm) - 853 76 777jaw-hub-shaft (25mm) - 339 179 160

jaw max toward beam

Evolution of jaw-hub-shaft25mm deep cooling tubes

SS 1hr beam

Transient 10sec @12min beam

RC1 – not a practical support scheme

More

realistic

Note reduced shaft end deflection – a positive result if stop is used

Next for jaw-hub-shaft:

Alternative materials to reduce shaft deflection


Simple support, deflections referred to jaw edge or shaft

po

we

r (k

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r ja

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Tm

ax

( C

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r (k

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deflections referred to jaw edgeCu, 136x71x950- , cooling 25mm deep, 5cm pitch 11.7 86.5 394 58.5 231 1216 RC1 baseline

Cu, 136x11x950- , solid, cooling 25mm deep, 5cm pitch 11.7 75.5 253 58.5 209 919 baseline + solid

Cu, 136x11x950- , solid, cooling 25mm deep, 2cm pitch 11.7 65.7 202 58.5 195 813Cu, 136x11x950- , solid, cooling 10mm deep, 2cm pitch 11.7 54.3 136 58.5 159 606 baseline + solid, shallow, 2p

Simple support, deflections referred to shaftCu, 136x71x950- , cooling 25mm deep, 5cm pitch 11.7 86.5 426 58.5 231 1260 RC1 baseline


Cu, 136x11x950- , solid, cooling 25mm deep, 2cm pitch 11.7 65.7 238 58.5 195 853 refined baseline

Cu, 136x11x950- , solid, cooling 10mm deep, 2cm pitch 11.7 54.3 171 58.5 159 646 base + solid, shallow, 2p

Cu, solid shaft, 25mm, 2cm pitch 11.7 66.3 100 58.5 197 339 jaw-hub-shaft

Cu, solid shaft, 10mm, 2cm pitch 11.7 54.7 78 58.5 160 280Cu, super invar shaft, 25mm, 2cm pitch 11.7 67.4 90 58.5 199 266 super invar shaft

Cu, tungsten shaft, 25mm, 2cm pitch 11.7 66.8 88 58.5 198 270 tungsten shaft

Cu, sst shaft, 25mm, 2cm pitch 11.7 67.3 132 58.5 199 368 sst shaft

Cu, Be shaft, 25mm, 2cm pitch 11.7 66.7 112 58.5 198 368 Be shaft

Glidcop AL15, solid, cooling 25mm dp, 2cm pitch 11.7 68.6 103 58.5 205 348 all Glidcop

SS @ 1 hour beam life transient 10 sec @ 12 min beam life

Alternative Shaft MaterialsShaft supported case - Slight Improvement

Deflection is combo of bending & swelling


Spring-supported ends, center stop at 45 degrees, deflections referred to stop

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r (k

W)

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r ja

w

Tm

ax

(

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(um

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r (k

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(

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(um

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jaw

Cu, 136x71x950- , cooling 25mm deep, 5cm pitch 11.7 86.5 36 58.5 231 97 RC1 baseline


Cu, 136x11x950- , solid, cooling 25mm deep, 2cm pitch 11.7 65.7 24 58.5 195 76 refined baseline

Cu, 136x11x950- , solid, cooling 10mm deep, 2cm pitch 11.7 54.3 22 58.5 159 64 baseline + solid, shallow, 2p

Cu, solid shaft, 25mm, 2cm pitch 11.7 66.3 48 58.5 197 179 jaw-hub-shaftshaft

Cu, solid shaft, 10mm, 2cm pitch 11.7 54.7 34 58.5 160 135Cu, super invar shaft, 25mm, 2cm pitch 11.7 67.4 48 58.5 199 192 super invar shaft

Cu, tungsten shaft, 25mm, 2cm pitch 11.7 66.8 47 58.5 198 184 tungsten shaft

Cu, sst shaft, 25mm, 2cm pitch 11.7 67.3 50 58.5 199 180 sst shaft

Cu, Be shaft, 25mm, 2cm pitch 11.7 66.7 46 58.5 198 179 Be shaft

Glidcop AL15, solid, cooling 25mm dp, 2cm pitch 11.7 68.6 51 58.5 205 186 all Glidcop

SS @ 1 hour beam life transient 10 sec @ 12 min beam life

Alternative Shaft MaterialsCentral stop-supported case - No Improvement

Note: values in table manually adapted from simulation results based on jaw edge or shaft end supports. Stop located in mid-jaw at 45 degrees from point closest to beam.


shaft end deflection eff lengthdeflection reference jaw edge shaft stop stop n/a n/abaseline (25mm) 394 426 36 390 394 0.43refined baseline (25mm) - 238 24 214 202 0.63jaw-hub-shaft (25mm) - 100 48 52 221 0.51

baseline (25mm) 1216 1260 97 1163 1216 0.24refined baseline (25mm) - 853 76 777 913 0.31jaw-hub-shaft (25mm) - 339 179 160 881 0.25

jaw max toward beam

Evaluate jaw-hub-shaft25mm deep cooling tubes


SS 1hr beam

With stop

con: 2x deflection

pro: 75% reduction of shaft motion

Shaft support only

con: 4x deflection

pro: simpler mechanism, same control architecture as Ph I

4x2x

Note: deflection means deviation from straight (in um). Eff length is length of jaw (in m) deflected <100 um compared to maximum deflection point.

New Baseline


Permanent DeformationInitial condition: 1 hr beam lifetime heating rate. Transient: 10 seconds heating at 12min beam lifetime rate followed by 50 seconds cooling.

Copper Glidcop AL15


Permanent Deformation

Permanent Deflection – deviation from straight (um)

Refined baseline 73

All Cu shaft-hub-jaw 62

All Glidcop AL15 shaft-hub-jaw ~0

Permanent bending of jaw after one transient heating cycle. Deflection is concave as seen from beam. Glidcop AL15 effectively prevents plastic deformation.


Further refinements

• Optimize hub length, location

• Hub region solid Cu, two stub shafts of alternative material, butted to hub

• Shallow cooling tubes (~15mm)

• Glidcop only where necessary – outer radii


Xtra Slide




jaw max toward beam

Evolution of jaw-hub-shaft25mm =>10mm deep cooling tubes



jaw max toward beam

SS 1hr beam


SS

Transient

LARP Phase II Secondary Collimator RC1 Prototype Engineering Status 6/21/06

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