### 5.1.6 Magnet Production[^1] {#magnet-production .unnumbered}

Many magnets need to be produced for the stage 1 VLHC. These include the
transmission line magnet, *etc, etc, etc, (list other magnets here).
List each type of magnet and make reference to the section which
includes general features and/or requirements of each.*

#### 5.1.6.1 Transmission Line Magnet Fabrication {#transmission-line-magnet-fabrication .unnumbered}

This section includes fabrication details and schedules associated with
the transmission line magnet. It includes a description of a proposed
factory necessary to build the magnets and a brief description of the
magnet fabrication process. Labor required, as well as a production
schedule are outlined. Costs are not included in this section.

3160 magnets, each 65 meters long, need to be fabricated over a six year
period. This will require approximately two magnets to be completed per
day, five days a week Details of the magnet assembly are shown in
section *5.1.2?* of this report.

##### 5.1.6.1.1 Factory Construction {#factory-construction .unnumbered}

Transmission line magnet fabrication takes place in a factory with an
approximate size of *120 meters by 200 meters.* A floor plan of the
assembly factory for the 65 meter long magnet assembly is shown in
Figure 1. *This figure needs to be modified to be readable, with some
areas enlarged, maybe split into multiple figures.*

![](media/image1.wmf){width="6.104861111111111in"
height="3.6555555555555554in"}

Figure 1. Transmission Line Magnet Assembly Factory Floor Plan

*Need a detailed description of the factory construction here, with
something said about construction of the tooling. Details about tooling
design can be deferred until the fabrication section, or , more likely,
a referenced TD note.*

#####  5.1.6.1.2 Magnet Assembly {#magnet-assembly .unnumbered}

Assembly of the transmission line magnet for the VLHC Stage 1
accelerator consists of eight steps. The assembly procedure is described
in detail in reference \[1\], and is summarized below.

###### Assembly of Drive Transmission Line for Stage 1. VLHC

1\. Mount 6 invar pipes to assembly table (area #1 in Figure 1), each 12
meters long, and weld together into one continuous section using
automatic rotary welding heads. The tube is inspected mechanically.

2\. The assembly is moved to Area #2 for the transmission line assembly.
Tooling pulls the copper and superconducting braids over the invar tube.
Copper tape is spiral wrapped over the assembly. The outer tube is fed,
in 12 meter sections, over the taped assembly, then welded in the same
manner as the inner tube.

3\. The completed assembly is moved to Area #4 to be leak checked.

4\. The transmission line is moved to Area #3 for ball swaging. 3
carbide balls, each of increasing diameter, are pulled through the inner
tube, swaging out the diameter and compressing the braid between the two
tubes.

5\. The line is moved to Area #5 for the cryostat assembly. Injection
molded Ultem cold support rings and extruded aluminum 50K thermal shield
sections are automatically fed onto the transmission line from the end.
Trace tubes for 60K helium are installed on the sides. 30 layers of
superinsulation are individually spiral wrapped onto the shield, while
the cryostat rotates on the assembly table. Tooling will punch holes in
the insulation as it is being wrapped, to accept the penetrations from
the support rings. The extruded aluminum vacuum jacket is then fed over
the insulated assembly in 12 meter sections, and welded.

6\. The drive transmission line, complete with cryostat, is moved to
Area #4 for leak checking and final inspection. It is then moved to
storage to wait for installation into the iron. Total time to fabricate
a drive transmission line is approximately *27* hours.

Assembly of the transmission line will require somewhat complex tooling
which must perform seven types of automatic processes; automatic rotary
welding, feeding parts longitudinally onto pipes, pulling copper and
superconducting braid onto pipes, wrapping copper tape and
superinsulation, installing trace tubes, and pulling carbide balls
through the assembly to swage the inside diameter. A pictorial
representation of each of these processes are shown in Figures 2 through
7.

![](media/image2.jpeg){width="4.600694444444445in"
height="2.9180555555555556in"}

Figure 2. Tube welding operation

![](media/image3.wmf){width="4.151388888888889in"
height="2.433333333333333in"}

Figure 3. Feeding parts onto assemblies

![](media/image3.wmf){width="4.151388888888889in"
height="2.433333333333333in"}

Figure 4. Pulling Braid

![](media/image3.wmf){width="4.151388888888889in"
height="2.433333333333333in"}

Figure 5. Installing Trace Tubes

![](media/image3.wmf){width="4.151388888888889in"
height="2.433333333333333in"}

Figure 6. Wrapping superinsulation

![](media/image3.wmf){width="4.151388888888889in"
height="2.433333333333333in"}

Figure 7. Ball Swaging

###### Assembly of the Return Transmission Line 

The return transmission line design is similar to the drive transmission
line, except a slightly larger size. The return transmission line is not
surrounded by an individual cryostat, as was the drive line. Instead, it
is included in the cryopipe assembly.

Fabrication scenario is identical to that given for the drive assembly
in part A, steps 1-4. Approximate time required is *15* hours.

###### Fabrication of Cryopipe Assembly

1\. Weld the 6.5K flow return pipes, the 40K Shield Supply header, and
the 70K Shield Return Header pipes together longitudinally. Mount pipe
sections to assembly table (area #1 in Figure 1), each 12 meters long,
and weld together into one continuous section using automatic rotary
welding heads. The tubes are inspected mechanically, then stored.

2\. Transport the three pipes, together with the Return Transmission
line, to the assembly station. Assembly station is shown in Figure 8.

![](media/image3.wmf){width="4.151388888888889in"
height="2.433333333333333in"}

Figure 8. Cryopipe Assembly Station

3\. Mount and align four pipes at assembly table.

4\. Feed 34 spiders over pipes, spaced every two meters. *Is this done
by hand?*

5\. Attach shield sections. They are each two meters long, and will clip
on between each spider *as shown in Figure 9*.

![](media/image3.wmf){width="3.845138888888889in"
height="2.254166666666667in"}

Figure 9. Shield Sections being attached.

6\. Attach (*xxx*) braids to intercept from 4.5K with connection to
6.5K.

7\. Apply superinsulation. The superinsulation consists of 60 layers of
aluminized mylar. Three blankets, each 19 meters long, and one blanket
10.5 meters long, each 30 layers thick are wrapped around the cryopipe
assembly. The 10.5 meter layer is at the opposite end on either side, so
that the gaps between the layers are staggered. The blankets are wrapped
so that they are also staggered azimuthally, so that the azimuthal
cracks are not coincidental, allowing a minimum of 30 layers of
superinsulation to cover any crack. Each of the layers is wrapped with a
different azimuthal starting point, so that the longitudinal cracks are
not coincidental.

8\. Inspection of some kind?

9\. Transport to storage area. Time required to fabricate a cryopipe
assembly is approximately *11 hours.*

D. Assembly of the beam tube and vacuum pumping chamber

1\. Transport Parts to Beam tube Welding Station in 12 meter lengths.

2\. Align and Weld Parts longitudinally. The operation is shown in
Figure 10.

![](media/image3.wmf){width="3.9604166666666667in" height="2.31875in"}

Figure 10. Beam Tube Welding

3\. Leak Check

4\. Transport to beam tube storage area. Time required to fabricate two
beam tube assemblies is approximately *10 hours*.

###### E. Installation of iron and structural support over the cryopipe assembly and transmission lines. {#e.-installation-of-iron-and-structural-support-over-the-cryopipe-assembly-and-transmission-lines. .unnumbered}

1\. Transport Drive Transmission Line and Cryopipe Assembly to Iron and
Structural Support Assembly Table.

2\. Transport 12 meter long Iron and Structural Support sections into
position.

3\. Slide Structural Support Sections over Transmission line and
cryopipe assemblies. The sections move on a track assembly as shown in
Figure 24. All sections are transported from the same end. Each section
stops at a position which provides 5 cm of space between the section
being installed and the previous section.

![](media/image3.wmf){width="3.9784722222222224in" height="2.3375in"}

Figure 11. Iron and Structural Support Assembly

5\. The iron sections are aligned by pins. The section being installed
is moved into a precise position to allow a pin from the section being
installed to enter a hole in the previously installed section. The
section is then moved 5 cm into its final position. Then the sections
slide together and are attached.

8\. Two welds are made at each junction between Magnet Support Tubes.
Welds are made by two torches, simultaneously welding at 180 degrees
apart. *I no longer remember why we decided that two welds are made at
each junction.*

9\. Leak check of the magnet support tubes.

10\. Final Inspection of the Iron and Structural Support Assembly. This
operation takes approximately *14 hours*.

###### F. Measurement of the magnetic field of the assembly. {#f.-measurement-of-the-magnetic-field-of-the-assembly. .unnumbered}

As a quality control measure and to characterize the magnetic field, all
magnets are measured magnetically. This must be done before the beam
tube and vacuum pumping chamber is installed, because the test probe
must be placed in the area occupied by the beam tube. 90% of the magnets
will be measured with the transmission line at room temperature. 10%
will be measured with the transmission line cooled to cryogenic
temperatures. During the initial stages of production, we could choose
to cold test a larger fraction of magnets or lengthen the duration of a
cold test. No doubt we would do some of both.

The test stands are capable of testing 2 per day at room temperature,
and 1 per week cold. The test cycle is shown below. If the test is done
with the transmission line warm, *steps 2, 4, 16 and 18* below are
deleted.

1\. Install Magnet on stand - 4 hr.

2\. Make cryogenic connections - 4 hr.

3\. Make electrical connections. - 4 hr.

4\. Cool down transmission line. - 16 hr.

5\. Set up probe insertion structure. There are a total of 10 probes,
each 6.5 meters long. Five probes, each spaced at 13 meter intervals,
are simultaneously positioned on each side of the iron structure, in
position to be inserted into the space to be eventually occupied by the
beam tube. -- 2 hr.

6\. Precise longitudinal position is verified. -- 15 min.

7\. Probes are inserted into measurement position "A". -- 15 min.

8\. Magnet is powered to 100 kA. Data is taken. -- 4½ hr.

9\. Probe structures are moved laterally out of the iron on each side.
-- 15 min.

10\. Probes move 6.5 meters longitudinally into second measurement
position. -- 30 min.

11\. Precise longitudinal position is verified. -- 15 min.

12\. Probes are inserted into measurement position "B". -- 15 min.

13\. Magnet is powered to 100 kA. Data is taken. -- 4 ½ hr.

14\. Probe structure moves laterally out of the iron on each side. -- 15
min.

15\. Measurement tooling is removed. -- 2 hr.

16\. Warm up transmission line. -- 16 hr.

17\. Disconnect electrical connections. -- 4 hr.

18\. Disconnect cryogenic connections. -- 4 hr.

19\. Remove Magnet from Stand -- 4 hr.

*This operation takes approximately 30 hours for a warm test and 70
hours for a cold test.*

A schematic of the test cycle is given in Table 1.

Table 1 Test Cycle

  ----------------- ----------------- ----------------- -----------------
  task              description       duration          

  precycle          0-100kA-0@100 A/s 2x1000 s          33 min

  up ramp           Iinj on-the-fly,  1000              17 min+60 min+5
  measurement       Imax              s+tinj+tflattop   min
  cycle, pos\'n A                                       

  down ramp         on-the-fly        1000 s            17 min
  measurement                                           
  cycle, pos\'n A                                       

  precycle          0-100kA-0@100 A/s 2x1000 s          33 min

  up ramp           Iinj on-the-fly,  1000              82 min
  measurement       Imax              s+tinj+tflattop   
  cycle, pos\'n B                                       

  down ramp         on-the-fly        1000 s            17 min
  measurement                                           
  cycle, pos\'n B                                       

  total (excluding                                      2.5 hr
  setup)                                                
  ----------------- ----------------- ----------------- -----------------

Details of the individual probe configuration and magnet measurement
process are explained in Section 5.1.7. *(or possibly here, with section
5.1.7 eliminated).*

###### G. Installation of the beam tube and vacuum pumping chamber {#g.-installation-of-the-beam-tube-and-vacuum-pumping-chamber .unnumbered}

1\. Beam Tube Assembly is mounted onto Structural Support.

2\. Beam Tube Assembly is installed. *They are installed from the side.
On half the assemblies, the beam tube must be "sprung" into position
somehow, but then will stay in position after it is installed. On the
other half, it will slide into position easily, but will need to be
secured afterward. Show two figures, one of the beam tube and pumping
chamber being installed, showing how it is sprung, and one with it being
secured into the structure after installation.* This operation requires
approximately *5 hours.*

![](media/image3.wmf){width="3.686111111111111in"
height="2.157638888888889in"}

Figure 12. Installation of Beam Tube and Vacuum Pumping Chamber

###### H. Final inspection of the assembly {#h.-final-inspection-of-the-assembly .unnumbered}

*Don't know yet what this involves. Call it 2 hours as a placekeeper.*

##### 5.1.6.1.3 Schedule {#schedule .unnumbered}

The magnet construction factory is designed to produce two magnets per
day, accomplished in approximately 2 shifts. Each "area" shown in the
factory floor plan would function as an independent operation, dedicated
to constructing an individual component or accomplishing a specific step
of the assembly process. A third shift would be used to move parts
between areas to the appropriate place for the next day's work.

Reference \[2\] shows detailed schedules for each sub-assembly
manufactured for the transmission line magnet, with times elapsed for
each individual operation described in section 5.1.6.1.2. "Throughput"
schedules for each work area are also shown.

Figure 13 displays a diagram representing a typical week of work for the
factory, in which ten complete magnets are fabricated and tested. The
times indicated for each operation are shown in reference \[2\].

![](media/image4.wmf){width="5.7972222222222225in"
height="7.451388888888889in"}

*Figure 13. Transmission Line Magnet Workweek Diagram*

*About ½ page of text, explaining the diagram, describing the amount of
manpower needed for each station, giving a total manpower estimate for
one week's work, and manpower for the total fabrication project, will be
included here.*

#### 5.1.6.2 Other Magnets {#other-magnets .unnumbered}

*Similar information about the other magnets needed? Are there other
magnets which need to be covered in similar detail in this section? This
will add a lot of length to the section, and will require significantly
more cutting or condensing elsewhere.*

*Section is still about 3-4 pages too long. Some figures will probably
need to be cut, or text further condensed.*

#### References {#references .Reference-heading .unnumbered}

\[1\] J. Carson, R. Bossert, \"A Proposed Production Procedure for Stage
1 Transmission Line Magnets\", TD-01-xxx, 2001.

\[2\] J. Carson, R. Bossert, \"Throughput for Stage 1 Transmission Line
Factory\", TD-01-yyy, 2001.

[^1]: original source file:
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