LARP LHC PHASE II COLL RC1 TESTS S. Lundgren 16 May 2006 No 1 22

1
LARP Phase II Secondary Collimator RC1

• Collimator Test Program
• Revised 5/15/06

2
LARP Phase II Secondary Collimator
RC1Collimator Test Plan

• Near term
• Jaw/Cooling Tube Joint Development
• Single Jaw Thermal Tests
• Later this year
• Design and fab hardware for Mechanical Prototype
  Tests

3
Jaw/Cooling Tube Joint DevelopmentPurpose
determine appropriate joint configuration
fabrication methods

• May 18th
• Cooling Tube
• Jaw Center
  Mandrel

• In process.. target completion date
• Square hollow magnet conductor for first test 9
  mm x 9 mm
• Copper jaw and mandrel
• Cu-Au braze
• After first braze, machine coil o.d. for correct
  fit to jaw i.d.
• After second braze, section assy to inspect
  coverage
• Round tubing with grooved (?) mandrel is next

70 mm dia
100 mm dia
100 mm
4
Jaw/Cooling Tube Joint Development

• Cooling Tube cross-section Options
• Preferred method is round tubing in a D shaped
  groove
• Flattening of tube can be done by rolling with
  alcohol lubricant in clean environment
• May require several groove shape attempts to
  obtain braze uniformity (will start with .5 mm
  flattening of tube)
• Material should be available in Copper Alloy 101
  OFE Class 2 ASTMF- 68
• Square tubing in square groove requires a
  machining step prior to second braze
• This may be a difficult machining operation
  without lubrication
• Material availability may be a problem
• Only certain od/id combinations are available
• Chemical composition is a concern wrt (see above)

5
Jaw/Cooling Tube Joint Development

• Determine Mandrel/Cooling Tube features and
  develop the winding process
• Select constant or varying pitch grooves (ANSYS)
  (Eric)
• Design dummy parts for round tube test (Steve)
• Design tightening feature for center u-bend
  location
• Determine if bend radius is adequate to prevent
  crushing
• Perform tight radius bends in tube with/without
  cerrobend or other recommended material (to
  prevent crushing)
• Perform preliminary winding test(s)
• Develop best winding techniques for manufacturing
  process
• QA assembly prior to brazing with ball test of
  completed Mandrel assembly (80 diameter
  spherical bead)

6
Jaw/Mandrel/Cooling Tube RD Plan Forward
Square Cooling Tube Braze Test
Today
Machine od of coil to clean up winding
deformation
Square Tube is currently brazed to mandrel
Machine id of Jaw to suit coil od
Document results with photos and writ-up
of complete process
Braze assembly together
Machine into sections to inspect braze joint
7
Jaw/Cooling Tube Joint Development

• Ready for brazing

8
Jaw/Cooling Tube Joint Development

• Glidcop Test Jaw showing D groove, entrance and
  exit ports for cooling tube

Copper plating (.05mm thick) is required on outer
surface prior to brazing on the OFE copper tubing
Plating, winding, rolling and brazing techniques
will be developed during this test
9
Single Jaw Thermal Test Hardware

• Long lead items (2-6 weeks)
• 2x Heater controllers are on order due mid June
• Ready to buy 4x 5kW electric resistance heaters
  (380 mm long)
• Ready to buy Glidcop material for 1 Jaw (2
  Halves)
• Ready to buy Glidcop material for 1 Mandrel
• Ready to buy molybdenum matl for Shaft (2
  Halves) (vendor stock)
• Heater Mount
• Determine appropriate material
• Design Mount profile for reasonable heat flow
  into facet
• Mount sections are 25 mm long to minimize effect
  on Jaw stiffness
• Bore to be .05 mm dia oversize of actual heater
  size (15.88 mm dia)
• Attach to facet by brazing (hold in alignment
  with dummy heater)
• Thermocouple attachments in Jaw
• Locations, depth, size, electrical isolation
  features in Glidcop Jaw

10
Single Jaw Thermal Test Hardware contd

• Jaw Support( bearings and mount)
• RC1 Bearings
• Mount them on V blocks or?
• Rigid mounting for capacitance sensors
• Locate at ends and center of Jaw

11
Single Jaw Thermal Test Hardware
12
Single Jaw Thermal Test Hardware

• Cooling Coil/Mandrel/Shaft Assembly

13
Cooling Coil/Mandrel/Shaft Assembly Section
When inlet and outlet cooling tubes exit the
shaft on the bearing axis each tube will twist on
its own axis when the collimator is rotated
14
Single Jaw Thermal Test Hardware

• Cooling tube entrance and exit detail

15
Single Jaw Thermal Test Hardware

• End View of Cooling Coil wound on to Mandrel

16
Single Jaw Thermal Test Hardware

• Glidcop Al-15 Half Jaw

Inner bore is tapered to facilitate assembly
Glidcop cost is 7884 each
17
Single Jaw Thermal Test Hardware

• Jaw / Heater / Sheath Assembly cross section

2x 5kW Heater
38x 25 mm long Heater Mount
Braze Mounts to Jaw facet
18
Single Jaw Test Thermocouple Locations

• Thermocouples are recessed into Jaw slightly
  below the surface
• Spaced along Heater length and equally spaced
  half way around Jaw circumference
• Should yield the Jaw heating profile predicted by
  the FE analysis

2 x 5kW Heaters 30 x Mount (brazed to Jaw)

• 16 x Thermocouples

19
Single Jaw Thermal Test Hardware
DAC Control Block Diagram
Heater 1 Controller
PC with LabView Software
Jaw Heater 1
Over Temperature Control
Heater 2 Controller
Jaw Heater 2
Capacitec Signal Amplifier
Jaw deflection sensors
DAC Signal Processor
Jaw thermocouples
20
RC1 Mechanical Prototype Test

• Purpose bench top testing of the jaw actuating
  mechanism in CERN orientations
• Vacuum tank with easy access
• CERN adjustment mechanism
• SLAC cooling water feed-throughs and flexible
  connections
• SLAC rotation mechanism
• Simplistic control system for jaw aperture
• Minimal instrumentation connections for position,
  temperature, etc.
• RC2 will incorporate LHC-compliant interfaces
• Heat loading may not be possible
• Use CERN Phase I components as appropriate

21
RC1 Mechanical Prototype
FY07 RC1 consists of jaws, tank actuators -
evaluated for horizontal (shown), vertical (90o)
and skew (/- 45o) orientations.
FY08, RC2
Variant use CERN vac tank, dummy jaws of correct
weight
22
Development/Test Lab