Laboratory

P.O. Box 500 • Batavia, Illinois • 60510

TD-03-042

September 2, 2003

## Technical Note

D. Pasholk

# *Fermi National Accelerator Laboratory*

# *MS 316, PO Box 500*, *Batavia, IL, USA*

#  Procedure for building a Solid Model of a Coil

> *Abstract---This technical note list the design parameters used for
> designing the Inner and Outer coil for the High Field Dipole or
> Quadrupole coils.*
>
> Introduction
>
> There are seven major steps involved in the creation of the conductor
> coil. The naming of the many different computer program data files and
> location in the coil must be clear. The seven steps are listed.

1.  Use program 'Sbend.' This program uses the provided input data files
    with the extension of .xin

2.  Use 'Win-Word' to create the data input files for each conductor
    group. Save with the extension of .inp.

3.  Use program 'Bendrx05.exe' to create the data files with the
    extension of .rox.

4.  Use 'nedit' to edit the .rox files, to separate the conductor groups
    into individual files of each conductor. Save as a numerical value,
    reprehensive of the conductor's location.

5.  Use 'I-deas' program file 'coil-surface.prg' to read the point data
    file.

6.  Use 'I-deas' to make the solid model of the coil.

Step 1.

Open a Unix window.

Enter Sbend

Enter 1 space 3 carriage return.

Enter file name for input. This file is provided, using the extension
.xin

Enter file name for output.

Use the naming convention: i = inner layer. r = return end. 1 = first
conductor group. This example of the file output name would be: ir1.xin.

The conductor group number is determined by counting the number of turns
the cable makes between the spacers or shoe and spacer.

Enter the conductor group YZ Inclination Angle.

This information is supplied from the HFDA04 tech note.

Enter ok.

Enter ok.

Expansion, enter the default.

Shift; enter the data from the tech note.

Bluntness, enter the data from the tech note.

Enter NO for: Do you want different values?

Enter a carriage return for. With narrows?

Enter NO for: Do you want centroids of the current density of the
cables?

Enter YES for: Do you want the corners of the cable?

Enter YES for: Do you want all the cable frames?

Enter a carriage return for all the problems.

Enter NO for: Do you want a shelf under this group?

Enter YES for: Do you want the inside lateral surface?

Enter YES for: Do you want the outside lateral surface?

Enter NO for: Do you want to continue with interactive control over...

Enter NO for. Free edges.

Remember for the Lead End you need the left side and the right side data
files. These files will have an 'l'=left or 'r'=right add to the file
output name. The Return End is symmetrical about the centerline.

Step 2.

Create the .inp files for each conductor group. You write this file for
each .cor file.

INP files have five lines with a data point in each line.

Open a Unix window.

Enter nedit.

Enter 1; this is the unit's conversion factor.

Enter 5; this is the number of conductors. To determine the number of
conductors for each group refer to the assembly drawings.

Enter 50; this is the number of rulings.

Enter 1; this is the number of subdivisions.

Enter 0 this is the origin difference.

Save the output file using the described naming convention, with the
extension .inp.

Step 3.

Open a Unix window.

Enter bendrx05.exe.

This program creates an output file with the x.y.z coordinates in groups
of four, which represent the cable cross-section corners of each ruling.

The file name must be the same as the .cor file.

Enter the file name, no extension. Make sure the two files .cor and .inp
are present.

Enter angle about the z-axis. (0).

Save the output file using the described naming convention, with the
extension .rox.

Step 4.

The .rox files contain the x, y, and z coordinate points for each
conductor in the conductor group. For example the inner lead end of
conductor group one has two conductors in it.

The .rox file has the data for each of the two conductors; they must be
separated into individual files.

Open a Unix window.

Enter nedit.

Enter the file name, with the extension .rox.

Remove the top two lines.

Remove all the date except for the conductor you want to separate.

Save as new name. Identify the conductor with a --n, n being the
numerical value of the conductors location in the group.

The extension name is the same. .rox.

Repeat steps 1-4 for: The inner left lead end, the inner right lead end,
the inner return end, the outer left lead end, the outer right lead end,
the outer return end and each conductor group for all.

Step 5.

Start Ideas

Open a new model file.

Select, File.

Select, Program files.

Select, Run.

Enter, H:\\solid coil\\coil-surface.prg

Enter, OK.

Enter, OK.

Enter data file name, with path: H:\\solid coil\\ilr1-1.rox.

Make sure display filters, wire frame, points visibility is toggled on.

![](media/image1.png){width="3.4027777777777777in"
height="2.1527777777777777in"}The program will run and create the four
corners points for each of the fifty locations along the conductor's
length.

See figure 1.

![](media/image2.png){width="3.3506944444444446in"
height="2.5277777777777777in"}

Next the program draws a spline through the corner end points to create
the 4 outside edges of the coil.

See figure 2.

![](media/image3.png){width="3.329861111111111in"
height="2.7777777777777777in"}

Next the program creates the surfaces of the coil.

See figure 3.

![](media/image4.png){width="3.8715277777777777in"
height="3.2777777777777777in"}

Select, Reflect, for Return End Parts only.

Select the part.

Select the YZ plane, and keep both.

Rotate about the y-axis 90 degrees and translate in to position.

Save the model file.

Manage Bins.

Put away.

Check into Library.

See figure 4.

Step 6.

All of the conductor groups, inner and outer, lead and return end
conductor parts have been created.

Join together the inner, lead end left and right conductor segments.

Rename, save and check into the library. Put parts away.

Get the outer, lead end left and right conductor segments on the
workbench.

Join together the outer lead end left and right conductor segments.

Rename, save and check into the library. Put parts away.

Create the straight portions of the coils.

Ideas note: The join command does not work on a selective basis. A
combination of adds, surface intersection, trim at curve, and stitch
surfaces are needed to get the coil into a completely solid form.

![](media/image5.png){width="6.027777777777778in"
height="4.444444444444445in"}