SQXF Cu Cable Winding Test at LBNL

Dan ChengDec 17, 2013

SQXF Winding Test

• Uses the HQ winding mandrel as a baseline– FNAL-supplied mandrel spacer (120 mm -> 150 mm)

eliminated need for significant tooling fabrication• Parts rapid-prototyped in-house with Accura 60

– BEND design– Pole islands, wedges, spacers, end shoes

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HQ Winding Tooling Modifications

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FNAL supplied spacer to fill space from 120mm to 150mm dia modified for mounting to HQ mandrel

Winding Objectives

• Compare between copper and real cable– Winding behavior (parts shapes)– “Fluffiness” of coil in azimuthal direction

• Data gathering– Record mandrel rotation per turns– Observe effects of winding tension

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Winding Parameters

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• CERN Cable HQ16UC0121D– 1.527 mm average thickness– 18.05 mm width– 0.59° keystone angle– Cable insulation

• Directly braided S2 Glass, 66 TEX, 636-sized• ~146-150 µm, but LBNL 10-stack measurements pending to confirm thickness

• Winding tool used on all turns• Initial 5 turns wound at low tension (~11-13 kg)• Remaining turns

– RE wound at low tension (11-13 kg)– LE wound at nominal tension (25-27 kg)

First Five Turns, LE, ~11 kg Tension

Nb3Sn Copper

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First Five Turns, RE, ~12 kg Tension

Nb3Sn Copper

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Turn 6, LE

Nb3Sn, ~12 kg TensionCopper (wrapped spacers), ~27 kg Tension

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Turn 6, RE, ~12 kg Tension

Nb3Sn Copper (wrapped spacers)

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2nd Spacer (T12), LE

Nb3Sn, ~12 kg Tension Copper, ~25 kg Tension

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2nd Spacer (T12), RE, 12 kg Tension

Nb3Sn Copper

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2nd Spacer (T13/14), LE

Nb3Sn, ~12 kg Tension~72° angle

Copper, ~25 kg Tension~68° angle

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2nd Spacer (T13/14), RE, 12 kg Tension

Nb3Sn~72° angle

Copper~74° angle

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End shoe (T22), LE

Nb3Sn, ~12 kg Tension Copper, ~25 kg Tension

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End Shoe(T22), RE, 12 kg Tension

Nb3Sn Copper

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Final angle, after azim. compression

~67° Copper, LE ~68° Copper, RE

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Summary of Turns 6-13

Turn Tension kg

Mandrel Ang.

Notes

Turn 6, LE 25.4 8° *Wrapped spacerTurn 7, LE 26.8 8° *Wrapped spacer 2Turn 8, LE 26.8 14°Turn 9, LE 27.6 15°Turn 10, LE 28.6 10°Turn 11, LE 26.8 12°Turn 12, LE 13.2* 8° Wrong tensionTurn 13, LE 29.5 17° Spacer inserted;

moved when winding

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Turn Tension kg

Mandrel Ang.

Notes

Turn 6, RE 13.6 9° *Wrapped spacerTurn 7, RE 12.7 18°Turn 8, RE 13.6 18°Turn 9, RE 10.4 12°Turn 10, RE 12.7 6°Turn 11, RE 13.6 10°Turn 12, RE 13.6 14°Turn 13, RE 12.7 9° Spacer inserted, did

not move

Lead End, ~25 kg Return End, ~12 kg

Summary of Turns 14-22

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Turn Tension, kg Mandrel Ang. Cable Ang. From horiz.

Turn 14, LE 25.9 12° 67°Turn 15, LE 26.3 8° 69°Turn 16, LE 26.3 13° 71°Turn 17, LE 24.9 12° 70°Turn 18, LE 25.4 11° 70°Turn 19, LE 24 10° 69°Turn 20, LE 26.8 16° 68°Turn 21, LE 25.9 14° 68°

Turn 22, LE 26.8 18° 68°

Turn Tension, kg Mandrel Ang. Cable Ang.From horiz.

Turn 14, RE 12.7 9° 73°Turn 15, RE 11.7 13° 73°Turn 16, RE 12.7 9° 73°Turn 17, RE 12.7 10° 75°Turn 18, RE 12.7 10° 78°Turn 19, RE 13.2 10° 72°Turn 20, RE 11.7 11° 69°Turn 21, RE 12.7 14° 68°

Turn 22, RE 12.7 10° 68°

Lead End, ~25 kg Return End, ~12 kg

Copper Cable Observations

• No popped strands– Same with the Nb3Sn winding test as well

• The cable did not form a concave shape at the ends, as observed in the Nb3Sn case

• Fluffiness of coil was virtually the same as with the Nb3Sn case– But cable seemed to want to “spring back” more, per

technician’s observation• Coil parts shape and fit seemed very similar between

both cables wound with same tension

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Tension effects

• Higher tension did not seem to cause the cable to fit against the spacers better– Still needed significant azimuthal compression after all

turns were wound– RE spacers fit tended to have similar gaps as seen in

the Nb3Sn winding test– LE spacers also have similar gaps as seen in the Nb3Sn

winding test• Angle of cable against the pole/spacers, however,

tended to be shallower with higher tension

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Summary

• The copper cable seems to behave reasonably well, compared with real cable– Parts shapes that don’t fit with one cable also didn’t

seem to fit the other

• Without final curing press, it is still hard to confirm the final endshoe shape– Midplanes of both needed more clamping for

position

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