CNGS Horns : Status
8 nov. 2003

NBI 2003 – KEK, Japan
7-11 nov. 2003

NBI 2003 - CNGS Horns Status
Presented by Sandry Wallon

1

CNGS Horns : Status
CONTENT
1.
2.
3.
4.
5.

Outline of the contribution
Design & studies
Manufacture & checkings
Mounting & adjustments
Summary
NBI 2003 - CNGS Horns Status
Presented by Sandry Wallon21. Outline of the contribution
Pions and kaons focused by
2 magnetic horns toward Gran Sasso

French contribution• 2 horns (included 1 spare horn)• 1 reflector• 2 cooling systems• 2 strip lines w/ fast coupling system• 2 sets of adjustable supports

NBI 2003 - CNGS Horns Status
Presented by Sandry Wallon

32. Design & studies

7.5 m long1600 kg of aluminium alloy (+ceramic, stainless steel, …)

Double pulses within 50 ms
Pulse duration : 6 ms (horn)
13 ms (reflector)
6 s cycle during 4 years (2 107pulses)
150 kA (peak), 5000 ARMS
Toroidal B field : 1.9 T max.

7.5 m long
2200 kg

NBI 2003 - CNGS Horns Status
Presented by Sandry Wallon

42. Design & studies
Full 3D designHorn

NBI 2003 - CNGS Horns Status
Presented by Sandry Wallon5

2. Design & studies
Other equipement
Fast Coupling System& striplines
inside chamber / gallery

Set of 3 adjustable supports

Fast Coupling System (FCS)
Striplines and FCS new design

Strip lines⇒ Worker’s protection duringloosening / tightening FCS(shielded chicane)⇒ Better confidence in FCS
functionality

Not shown : cooling system
NBI 2003 - CNGS Horns Status
Presented by Sandry Wallon

62. Design & studies
Misc. studies done toguaranty functionalities(especially for horn’s inner conductor)••••

StatusThermal : Deformation & Stress.
Done
Static : Straightness.
Stability : Buckling.
Dynamic : Fatigue-corrosion (4 years lifetime requested).

NBI 2003 - CNGS Horns Status
Presented by Sandry Wallon

72. Design & studies
Thermal study⇒ material behavior⇒ thermal expansion, stresses

Heat load (inner cond.)• 13 kW (Joule losses)• 5 kW (radiation)
Water curtain falling
onto inner conductor

NBI 2003 - CNGS Horns Status
Presented by Sandry Wallon

coeff convection 8

2. Design & studies
Thermal study∆T=5°C∆T=8°C∆T=24°C∆T=33°C

Tm˜40°C

stress-0.75 <∆Ldyn< 0.75 mm

1.5 mm ‘dynamic’ thermal
expansion enable by thin flange(thanks to a 1.2 mm enforced
displ. [∆Lm=1.2 mm])
NBI 2003 - CNGS Horns Status
Presented by Sandry Wallon

Cyclical thermal
stress-10 < σ < 10MPa92. Design & studies
Dynamic study⇒ fatigue strength

axi-symmetricvibration mode 1(140 Hz) movie
Pt 1 (mode 1; 1+2)

axi-symmetricPt 3 (mode 1+2)

vibration mode 2(360 Hz) movie

Pt 2 (mode 2; 1+2)
σecr = 54 MPa (mode 2) [1][1] : From Marek Kozien’s Ansys
study (Cern / Cracow university)

NBI 2003 - CNGS Horns Status
Presented by Sandry Wallon

mode 1, mode 2, mode 4 10

2. Design & studies
Fatigue strength

Warning
Infinite lifetime
do not exist!

thermal + mechanicalstresses :we are below theenvelope curve

NBI 2003 - CNGS Horns Status
Presented by Sandry Wallon

fatigue-corrosion, SN curve 6082 11

3. Manufacture & checkings
Large parts
StatusHorns 1 et 1b : done

Reflector : doneouter conductor

electrical connection
NBI 2003 - CNGS Horns Status
Presented by Sandry Wallon

123. Manufacture & checkings
Inner conductorsProduction status
Horns 1 & 1b : done
Reflector : in progress

Rigid flange checking(large) Electrons Beam welding machine

2 inner conductors after EB welding
NBI 2003 - CNGS Horns Status
Presented by Sandry Wallon

133. Manufacture & checkings
Shot penninginner conductors

Horn flanges’ checkings (after machining)→ Ultrasonic→ X ray→ geometricalHorn tronconical parts’ checkings(after machining)→ Dye penetrant

StatusHorns 1 & 1b : done
Reflector : production in progress

Horn inner conductors’ checkings (after welding)→ X ray (for welds)
Reflector : cheaper processes used• rolled & welded sheet• TIG welding• dye penetrant (welds)• 3D checking

NBI 2003 - CNGS Horns Status
Presentedby Sandry Wallon
2 innerconductors
after EB welding14

3. Manufacture & checkings
Inner conductor (final) checking
Spec required : 1 mm shape tolerance
Outer surface axis checking (straightness)clamp flanges
8 m long ‘bench’intermediate supports

NBI 2003 - CNGS Horns Status
Presented by Sandry Wallon

15

3. Manufacture & checkings
Inner conductor (final) checking (as done)outer surface axis checking (straightness)

StatusDone
Job done at Cern by• Ahmed Cherif (3D machine)• Dominique Missiaen (laser tracker)
NBI 2003 - CNGS Horns Status
Presented by Sandry Wallon

164. Mounting & adjustements

Horn’s mounting

BAD surprise
There’s a inner cond. non-conformity
2 sets of grooves are uncorrectly
locatedNBI 2003 - CNGS Horns Status
Presented by Sandry Wallon

174. Mounting & adjustements
Horn’s inner cond. non-conformity
Actions

StatusDone→ Crisis meeting!
→ Solution proposals→ 3D design & drawing jobs
→ Mini prod. readiness review→ Electrical insulators order→ New spider manufacture→ Outer conductor machining(new spiders locations)⇒ Σ = 2.5 months→ Find where do the mistake come from?
⇒ CAD (design) used as CAD (drafting)
Other gift : Inner cond was designed with
Euclid CAD soft, other parts and assemblies
with Catia CAD soft!
NBI 2003 - CNGS Horns Status
Presented by Sandry Wallon

184. Mounting & adjustements
Inner conductor straightness adjustment
Warning
Former picture
To be refreshed1. Put a self centering probe inside
inner conductor
2. Check probe position
3. Adjust wires tensile force until tofind correct alignment
4. repeat previous job for 2 others
cables sets

StatusWill be performed at (by) Cern within 2004
NBI 2003 - CNGS Horns Status
Presented by Sandry Wallon

194. Mounting & adjustements
Centering stems & electrical connection
adjustments
Warning
Former picture
To be refreshed

How to achieve interchangeability
between horn and spare horn?

Centering stems :position adjustment / inner conductor axis

Electrical connection :position adjustment / inner conductor axis

NBI 2003 - CNGS Horns Status
Presented by Sandry Wallon

204. Mounting & adjustements
Horn axis adjustment

Warning
Former picture
To be refreshed

2. Tighten / loosen 2 M12 screws(bottom screws) ⇒ vertical displ. ± 20 mm(top screws) ⇒ lateral displ. ± 20 mm

1. Loosen FCS / open strip lines /Unplug strip lines
NB connection plates to be machined
NBI 2003 - CNGS Horns Status
Presented by Sandry Wallon

21

5. Summary
Horn manufacture : done, except FCS (production
review within 1 month)
Reflector manufacture : done, except inner conductor(to be deliver within january 2004)
Non-conformity trouble : solved
Adjustable support : jack received, other parts to bemanufactured
FCS & Striplines : design to be completed(production review within 1 month)
Cooling system : ready for production review?
Mechanical tests in progress (S. Rangod, G. Maire) : picture
Electrical tests (horns, reflector, FCS) within 2004
NBI 2003 - CNGS Horns Status
Presented by Sandry Wallon22