# Presentation: 528061

## LARP Collaboration Meeting

- Racetrack Coil Fabrication
- Jesse Schmalzle, BNL
- 04/27/06

## SR Coil Fabrication

- Two short racetrack (SR) coils fabricated using LBL supplied tooling and coil parts:

## SR Coil Fabrication

- Coils assembled into LBL supplied support structure:
- Bladder pressurized to 4500 psi (31 MPa).
- Average shell stress = 7500 psi (52 MPa).
- Preparing for cold test, estimate end of May.

## LR Coil Design

- Long racetrack design closely matches that of short racetrack:
- Double layer pancake made from single length of cable.
- Transition between layers at lead end pole tip.
- Iron pole coated with aluminum oxide.
- Fiberglass sock cable insulation.

- Pole width (uncoated) = 37.19 mm (1.464 in.)
- Coil straight section length = 3.45 m (136 in.)
- Coil overall length = 3.61 m (142 in.)

## LR Coil Design

- Variations as dictated by increased length /experience with SR coils:
- Segmented pole – 5 segments
- Allow for release of winding tension
- Allow for differential expansion/contraction during reaction.
- Gaps at reaction start = .42 mm/m minimum.
- Full length stainless steel rails (SR used horse shoe).
- Aluminum oxide thickness increased to 0.25 mm (.010 in.) (SR used .13 mm (.005 in.)).
- Increased protection against shorts to pole.

## LR Coil Design

- Variations (continued):
- Trace and glass cloth cover rails (covered coil only in SR).
- Eliminate the need for precise cutting and placement that is required to cover the coil turns without covering the rails.
- Glass cloth added between layers
- Ease concern over greater potential for shorts between layers.

- Reaction stack up, cavity set by pusher (tooling):

## LR Coil Design

- Variations (continued):
- Instrumentation trace to include quench protection heaters.
- Increase argon flow during reaction.
- Improve removal of contaminates that may contribute to shorts to the pole.
- Use higher flow rate below 400 C as palmitic acid is vaporized.
- 25 cfh up to 400 C, then drop to 10 cfh (SR was 3 cfh throughout).

- Impregnation stack up, cavity set by pusher (tooling):

## LR Coil Design

- Coil Assembly:
- G10 sheet and SST skin installed over impregnated coil.
- Skins bolted to rails
- Keys align individual pole segments.
- Residual gaps in pole filled prior to impregnation.
- G10 shims between coil and rails sized based on cable & part measurements.
- Ends contained by pushers attached to rails.

## LR Coil Fabrication

- Insulated cable is transferred to winding spools:
- Measured & divided onto 2 pancake spools.
- One installed on winding machine carriage, other mounted above coil pole for use on second layer.
- Cable vacuumed and checked for debris using lump detector.
- Cable tension automatically monitored & controlled.

## LR Coil Fabrication

- Coil Winding:
- Semi-automatic computer controlled winding machine
- Existing machine, new platform and shuttle.
- Pneumatic clamps to hold coil while opposite side is wound.
- Wind on reaction base plate.
- 25 lbs cable tension.

## LR Coil Fabrication

- Reaction:
- Shim coil and close fixture to provide ~1000 psi (7 MPa) side load.
- Automatic computer controlled cycle.
- Gas tight oven with continuously flowing argon atmosphere.
- Supply fed directly into reaction fixture.

## LR Coil Fabrication

- Epoxy Impregnation:
- Lead stabilizer solder fixture mounts to base plate.
- Coil / Impregnation fixture to hang vertically in vacuum tank.
- CTD 101K epoxy resin.
- Automatic computer controlled cycle.
- 3 strip heaters/side–1500 Watts ea.

## LR Coil Fabrication

- Epoxy Impregnation:
- Fixture completely sealed.
- Epoxy fed into bottom of fixture.
- Outlet at top connected to resin trap.
- Top of trap connected back to vacuum tank.

## LR Coil Handling

- Fixture Lifting:
- Limit coil strain to less than .05% (1/4 of  conductor strain limit)
- Reaction & impregnation fixtures require only 2 point support.
- Beams mount to sides of fixture in 2 places, lift from center.
- Use for:
- Transport
- Up-righting
- Flipping
- Max Strain < .01%
- Max deflection < .003” (.08 mm)

## LR Coil Handling

- Support Fixture Lifting:
- Collars clamped around shell.
- Same beams / spreader as reaction & impregnation fixture lifting.
- Up-right and hang in prep stand for connection to testing top hat.
- Max strain < .01%.
- Max deflection < .003” (.08mm).

- Coil Lifting:
- Beam picks up coil using holes in rails.
- Max strain < .01 %
- Max deflection < .001” (.03 mm)

## LR Coil Handling

- Prep Stand:
- Hang impregnation tool for mounting to vacuum tank top plate.
- Hang coil support structure for mounting to vertical cold test dewar top plate.

## LR Assembly

- Insertion of coils into support structure.
- Existing long flat table.
- Existing hydraulic cylinder
- Coil insertion.
- Bladder removal.

## LR Part / Tooling Status

- Coil Parts:
- Drawings released, shop is fabricating, completion estimate 4/28/06.
- Winding machine shuttle and clamps:
- Drawings released, shop is fabricating, completion estimate 4/28/06.
- Reaction tooling:
- Drawings released, shop is ordering material.
- Reaction oven:
- Order placed with L&L, estimated delivery 7/7/06.
- Impregnation tooling:
- Drawings released, shop is estimating.
- Fixture lifting beams & coil lifting beam:
- Drawings released, material on order, completion estimate 5/30/06.

## LR Plan and Schedule

- Copper coil, estimate start winding 6/15/06.
- Wind and impregnate only.
- Required parts, expected dates:
- winding machine, 5/25/06.
- reaction base plate, 6/15/06.
- coil parts, 5/30/06.
- impregnation tooling, 6/22/06.
- lifting fixtures, 5/30/06.
- Coil Production, estimate start winding 8/7/06.
- 2 coils from good cable, 3rd if necessary.
- Required parts, expected dates:
- reaction tooling, 7/14/06
- reaction oven (installed & tested), 8/21/06.
- Coil Assembly, estimate start 11/1/06.
- Cold testing, estimate start 12/27/06.