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IBL Package Overview: Cable Integration and iFlex Specifications

This overview provides detailed specifications for the IBL Package, focusing on the iFlex Type 01 bundles and their integration requirements. Key dimensions include critical lengths, sealing rings, and stiffness setups, which are vital for ensuring proper cable assembly and performance. The document highlights the importance of precise lengths between the cable board and potting to avoid integration issues. Attention to these mandatory key points will help achieve optimal sealing and functionality within the IBL package and prevent critical stresses during operation.

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IBL Package Overview: Cable Integration and iFlex Specifications

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  1. IBL TYPE 01 CABLES AND INTERMEDIATE FLEXES

  2. IBL PACKAGE OVERVIEW Sealing ring Staves iFlexes Type 01 bundles IP=0mm End of stave: 377 mm iFlexes: 693 mm IPT service ring 01: 912 mm IPT service ring 02: 1423 mm IPT service ring 03: 1984 mm IPT service ring 04: 2544 mm IPT service ring 05: 3250 mm End of IPT: 3386 mm

  3. SERVICES INSIDE IBL PACKAGE IPT SERVICE RING 1 + Z STOPPER IPT SERVICE RING 2 IPT SERVICE RING 5 + Z STOPPER PP1 IP IPT SERVICE RING 3 IPT SERVICE RING 4 STAVES iFlexes IPT SERVICE RING 1+ Z STOPPER

  4. iFlex test setup • iFlex stiffness setup goal: force vs displacement • In nominal position with respect to CAD, the resulting force is 4.5 N: • Need to guaranty the final shape of the iFlex or set up the nominal iFlex positioning at 0 N force with final material. • Need to strain relieve the PP0 area to assure a safe mating of connectors

  5. Bundle z stopper • Prototypes in production for testing onto the thermal mockup (see mockup team presentation) • Design made according to last bundle dimensions sent by SLAC (Ø7.5 mm at cable board exit). • Dot of glue for pipe • Potting for bundle Ø8

  6. TYPE01 BUNDLE • Nominal length between cable board and potting is 2452 mm. • We added 7 mm additional length for: • Thermal contraction (3mm) • Manufacturing tolerances (+-1mm) • Installation clearance • CAD and thermal mockup shows that 7 mm is the maximum overlength that we can integrate without compromising the integration

  7. TYPE01 DRAWING:ATUIBLP_0034

  8. TYPE01 BUNDLE MANDATORY KEY POINTS • The distance between the cable board and the potting must be precise: • Not enough overlength in cold phase if too short • Integration problem if too long • LAPP requested two different lengths for the power bundles and a diminution of the data bundle length for wrapping issue

  9. TYPE01 BUNDLE MANDATORY KEY POINTS • The two bundles after exiting the potting at PP1 must only be covered with shielding braid: • EMI connection • Integration issue on IPT extremity ring • LAPP test shows that a 6 mm bundle can fit Power bundle data bundle Cooling fitting

  10. TYPE01 BUNDLE MANDATORY KEY POINTS • NTC sensor location: • Modeling according to E.VIGELOAS tests at CPPM • Bonded on the sleeve • What is the connection location on CB and the number of sensors to implement ? NTC sensor

  11. CONCLUSION • The iFlex must be manufactured with respect to drawing in order to avoid critical stresses in the PP0 area and a possible de-mating. • The overlength between the cable board and the PP1 potting is critical for integration and should be precisely checked. This is also the case for the location of the Z stoppers during the potting stage. • The potting and bundles diameters are mandatory for an efficient seal and allow the bundle integration in the IBL package. • The length of the data and the power bundle must be respected to make the wrapping on the BP extender.

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