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Activities

Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnets at CERN. R. Beltron, J. Billan, O. Dunkel , L. Gaborit, P. Galbraith, J. Garcia-Perez, D. Giloteaux, B. Girod. Activities. AC-Mole. Coils. Optical Mole.

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Activities

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  1. Coil Manufacture, Assembly and Magnetic Calibration Facility for Warm and Cold Magnetic Measurements of LHC Superconducting Magnetsat CERN R. Beltron, J. Billan, O. Dunkel, L. Gaborit, P. Galbraith, J. Garcia-Perez, D. Giloteaux, B. Girod 14th International Magnetic Measurement Workshop26-29 September 2005, Geneva, Switzerland

  2. Activities AC-Mole Coils Optical Mole Sectors Level meter Dipole Connector Quadrupole Moles Coil area surface Long shafts Soft soldering Calibration DIMM Assembly Block 4 Parallelism Radius QIMM Gradient 14th International Magnetic Measurement Workshop26-29 September 2005, Geneva, Switzerland

  3. Contents 14th International Magnetic Measurement Workshop26-29 September 2005, Geneva, Switzerland

  4. Coil Manufacture – semi-automatic Winding machines for race track, solenoid and toroidal coils Meteor M101 B FUR DBA-S Toroidal coils: Race track [and solenoid] coils: • Single wire Ø 30µm - 150µm • [up to 1mm for solenoids] • Coil length from 18mm to 260mm • Coil width up to 30mm (more if needed) • Up to 3.000 turns (and more…) • [up to 30.000 turns for solenoids] • Coil cores from G10, Delrin (in general) • Single wire Ø 0.08mm to 1.8mm • Single or multi-layer, with separators • Core inner Ø 30mm min. • Core outer Ø 200mm max. • Various materials for coil cores 14th International Magnetic Measurement Workshop26-29 September 2005, Geneva, Switzerland

  5. Coil Manufacture – semi-automatic Coil realizations on winding machines 50 mm Pickup coils from 18 to 260mm length Toroidal coil in winding process 280 mm 100 mm 60 mm Toroidal coils ready for delivery Solenoid for a cryogenic valve 14th International Magnetic Measurement Workshop26-29 September 2005, Geneva, Switzerland

  6. Coil Manufacture – manual Rotating support Multi filament cable • Multi-filament wire, up to 20 filaments Ø 60µm • Coil length from 260mm to 2000mm • Coil width up to 15mm (more if needed) • Up to 20 turns (square shaped cross section) • Coil cores from G10 (in general) Epoxy bond reservoir Manual coil winding facility Coil core 250 mm Selection of coils wound manually 14th International Magnetic Measurement Workshop26-29 September 2005, Geneva, Switzerland

  7. Coil Manufacture – manual 15 mm Wire folding Coil winding Polymerization Rotating support for coil core 14th International Magnetic Measurement Workshop26-29 September 2005, Geneva, Switzerland

  8. Coil Manufacture – manual 6 strands 8 strands 10 strands 20 strands Various multi – filament wires 14th International Magnetic Measurement Workshop26-29 September 2005, Geneva, Switzerland

  9. Coil Manufacture Coil cross sections 0.5 mm 6 strands 36 turns 0.5 mm 20 strands 400 turns Cross section of a single wire, race track coil, 1000 turns Cross section of multi-filament race track coils 14th International Magnetic Measurement Workshop26-29 September 2005, Geneva, Switzerland

  10. Coil interconnection and cabling • Manual soft soldering under binocular • Connection plates for each type of cable (single wire Ø 32µm to 20 strand wire) • Soft soldering of signal cables to coils • Connection of signal cables to external connector Binocular used for soft soldering Various connection plates 14th International Magnetic Measurement Workshop26-29 September 2005, Geneva, Switzerland

  11. Coil interconnection and cabling Example of an Interconnection scheme: 10 strand wire in a 20 strand connection plate 12 mm 4 mm Connection plates embedded in coil core, left: single wire, right: 20 strand wire 50 mm 10 mm Preparation for soft soldering of a 20 strand connector Signal cables connected to their coils All coils of a sector connected 14th International Magnetic Measurement Workshop26-29 September 2005, Geneva, Switzerland

  12. Measuring Head Assembly Sectors for long shafts: • Sectors for long shafts (high field probes) used for cold measurements of LHC dipoles and SSS • 3/5 race track coils (2/4 tangential, 1 central), length: 700-1200mm • Coil support: ceramics (Al2O3) Assembled dipole shaft: 13 sectors + 1 prolongation = 18.5m 37 mm 1300 mm Cross section of a sector for dipole measurements Subminiature electrical connectors Parts to be assembled 14th International Magnetic Measurement Workshop26-29 September 2005, Geneva, Switzerland

  13. Measuring Head Assembly Moles for Warm and Cold Measurements: • Low field probes used for warm magnetic measurements on dipoles and quadrupoles during magnet production in industries. • 3/5 race track coils (radial) for dipoles, coil length: 750mm • Coil support: G10 • Level meter, slip rings, pneumatic brake, rotating motor unit,etc. 1500 mm Parts and assembled DIMM-Mole AC-Moles: • High and low field AC probes used for geometric and magnetic axis measurements of LHC dipoles and quadrupoles • 4 tangential race track coils, coil length: 116mm • Coil support: G10 • Level meter,camera, corner cube, • rotating motor, slip rings, etc. AC Mole 14th International Magnetic Measurement Workshop26-29 September 2005, Geneva, Switzerland

  14. Measuring Head Assembly Heads and shafts for cold mass measurements in LHe: • High field probes used for harmonic and Gdl measurements on cold masses for SSS and corrector magnets, operating in liquid Helium. • 3/5 radial race track coils, coil length: 200mm to 1200mm • Coil support: G10 250 mm 1200 mm Shaft during assembly Parts and assembled shaft for measurements in LHe 14th International Magnetic Measurement Workshop26-29 September 2005, Geneva, Switzerland

  15. Measuring Head Assembly Prototyping and repair workshop: Adjustment table for Level meters Turning… Dynamic gluing table …milling… …drilling UV curing for coil gluing 14th International Magnetic Measurement Workshop26-29 September 2005, Geneva, Switzerland

  16. Magnetic Calibration The laboratory: • Several reference magnets installed in former ISR tunnel, good stabilization in temperature Reference quadrupole [1.5m] 15m cryodipole Assembly Soft soldering Grinding Reference dipole [2.5m] Short reference quadrupoles [0.3m, 0.5m] Power supply for reference dipole 14th International Magnetic Measurement Workshop26-29 September 2005, Geneva, Switzerland

  17. Rotation support Integrators and PC Dipole Magnetic Calibration Dipole reference magnet: • Effective aperture: l=2.5m, h=80mm, w=300mm • Field: 1T (stab.:10-5T), monitored continuously with NMR probe and periodically mapped • Field angle aligned to <0.1 mrad w/r gravity • Used for calibration of coil area, parallelism and absolute angle (up to 5 coils simultaneously) • Overall uncertainty: 2x10-4 (repeatab.: 5x10-5) NMR probe Lateral stroke Sensor (res. 10-3mm) Integrators and PC Quadrupole reference magnet: • Magnet aperture: l=1.5m, Ø 125mm, • Field gradient of 8.6 T/m (@ 480A) • Used for calibration of coil radii • (up to 5 coils simultaneously) • Overall uncertainty: 5x10-4 Quadrupole Rotation and centering support 14th International Magnetic Measurement Workshop26-29 September 2005, Geneva, Switzerland

  18. Magnetic Calibration 15 m LHC Cryodipole: • Mainly used for checks and improvements of warm measurement systems running in cold mass factories (real size checks) • No diode mounted  no polarity limitation • Current limited to 15 A • First checks on reference magnet system (RMS) for LHC machine magnets DIMM-Mole measurements in 15m cryodipole Short Reference Quadrupole: • Magnet aperture: l=0.285m, Ø 70mm • Field gradient of 18.1 T/m (@ 352A) max. w. cooling • Mainly used for magnetic and geometric calibration of global and optical AC moles Calibration Results: AC-Mole measurements in short reference quadrupole • Calibration sheet  Traveller  Database 14th International Magnetic Measurement Workshop26-29 September 2005, Geneva, Switzerland

  19. Outlook What comes next? • Improvement of accuracy on Gdl calibration procedure • Extension of magnetic and optical calibration facilities for AC Moles • Development and tests of Reference Magnet System (RMS) • for LHC machine magnets • Extension of magnetic and optical calibration facilities for AC Moles • … life after LHC …??? 14th International Magnetic Measurement Workshop26-29 September 2005, Geneva, Switzerland

  20. Where are we at CERN? Coil Manufacture, Assembly and Calibration Facility CERN, bldg. 230 14th International Magnetic Measurement Workshop26-29 September 2005, Geneva, Switzerland

  21. Free Entrance ! ! ! Where are we at CERN? Come and visit…! Thank you for your kind attention… 14th International Magnetic Measurement Workshop26-29 September 2005, Geneva, Switzerland

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