Brrokshaven National Lab 4FO 6 Parker BNL Direct Wind Magnets

8/12/2019 Brrokshaven National Lab 4FO 6 Parker BNL Direct Wind Magnets

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presented by Brett Parker, BNL-SMDpresented by Brett Parker, BNL-SMD

BNL Direct Wind Magnets*BNL Direct Wind Magnets*

*In memory of Pat Thompson*In memory of Pat Thompson


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Outline: BNL Direct Wind Magnets

Overview production process and terminology.

Coil Winding, Wrapping, Measurement, and Curing

Planar Patterns versus Serpentine Coils

Multifunction, Multi-Layer Coils and Field Quality

.

ILC QD0 R&D Prototype and ATF2 Upgrade Magnets

Experience from Alpha (anti-hydrogen trap), HERA-IIand BEPC-II IR Magnets, and JPARC Correctors

eRHIC Final Focus Septum Magnet

15 September 2011 BNL Direct Wind Magnets,Brett Parker, BNL-SMD

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10 Basic Steps for Winding BNL Coils

1. Support tube is wrapped with epoxy substrate.

2. Insulated conductor with epoxy coating pays outunder stylus (7-strand cable or single strand).

3. Ultrasonic heating tacks conductor temporarily in

place (i.e. rapid cooling after stylus moves on).4. Coordinated motion: tube rotation, linear speed,

angle-of-attack, stylus pressure, power etc.

5. Fill gaps in pattern with G-10 (or Nomex) & wet

ILC QD0

Production

.

6. Then tension wrap with fiberglass for pre-stress.

7. Do a high temperature cure of the coil structure.

8. Occasionally we will machine coil on a lathe toensure that the outer coil surface is round.

9. For best field quality, measure harmonic contentof coil layers wound so far and prepare to makecorrections to harmonics in later layers.

10.As needed go back to step 1.


3

Octupole CoilTest Winding


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HERA-II Production Overview

ctWin

d,

ctWin

d,

Days

Days

15 September 2011 BNL Direct Wind Magnets,

Brett Parker, BNL-SMD4

BNLDire

BNLDire

Th

eEarl

Th

eEarl


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Planar patterns impact direct windcoil production in multiple ways




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The BEPC-II IR Magnet Design




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Initial BEPC-II: Look to go out of planeand wind dual-layer planar patterns.




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BEPC-II Special Feature: Local BES-IIIDetector Solenoid Compensation Scheme

8 layers


8

Local Compensation


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BEPC-II Quadrupole (SCQ) Winding


9


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Some Coil Topology Considerations

With Serpentine patternswe are able to bring leadpairs out without usingany extra radial space


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A JPARC coil option hadskew-quad leads brought

past the dipole and quadcorrection windings to fitinside main dipole coil.

Start lead is broughtout from layer #1

Lead Pair


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JPARC Corrector Design Summary


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Real coils: fillers, s-glass wrap, powerleads, volt taps and sometimes heaters.

G10 StabilizedLead Pair

Stycast AluminaEpoxy Filling

17 August 2011 BNL Direct Wind Magnets,Brett Parker, BNL-SMD

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The means to put s-glass prestress wrap on long thin tubes. And More!

Wrapper puts onand takes off at

same time

... for no netpull of long thincoil support tubes.

HeadDetailHeadDetail


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Alpha Antihydrogen Trap

CERNCOURIER


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QD0 and the ILC Experimental Detectors

1 IR & 2 Push-Pull Detectors


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QD0 sits inside the ILD (3.5 T) & SiD (5.T) detectors.


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Design for Compact SuperconductingMagnet Used in the ILC 14 mr Layout.

14 mr crossing angle via compactself-shielded QD0 coil windings.

Extracted beam passes just outside

coil into separate focusing channel. Cryostat to fit within limited space

inside detector at L* = 3.5 to 4.5 m.


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QD0 with active shield on/off

On Off


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Magnetic Measurements & Field Quality

When we need to meet the mostdemanding field quality goals ina multilayer coil, we make warmharmonic measurements aftereach coil set is completed andQuad Stack

subsequent coil sets based uponthese intermediate results.

A good example is the ATF2

superconducting upgrade finalfocus magnet coil production.


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All 3 coilsets nowcomplete

ATF2 Production


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Summary of Integral Field Quality in ATF2 Magnet

We calculated harmonics for Rref = 10 mm

to compare to the present ATF2 magnets.

The poorest quad harmonics (b3,a3), are

only 49. parts per million.

The areas highlighted in blue are all

smaller than 200 arts er billion.

ATF2Coils


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A Combined Function Magnet Trick.

Observe the following genericbehavior of the field with coildominated magnet geometry,the field strength reversescrossing the coil structure and

2 August 2011 eRHIC IR Magnet Designs,Brett Parker, BNL-SMD

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.

Thus on one side the combined external field isenhanced but on the other side the fields tend to

cancel; with a careful choice of relative strengthsand polarities we can create a low field region justoutside the coil structure for the e-beam to pass.


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Design Details for First IR Magnet

Dipole & Quadrupole Coil Sets

Low field region

Region used by circulatinghadron beam Neutrons

Magnet structure is aligned with e-beam.

Magnet offset is optimized for neutrons,circulating beam and early analysis for off-

momentum charged particle measurement.


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Peak field is 6.2 TPlot of |B| (Tesla) for the Coil Structure

or e- eam

Bo = 2.701 T

Gradient = -85.74 T/mand Lmag = 1.95 m

MagneticYoke


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Reduced Field Region for e-Beam

Even with 6.2 T coilpeak field and 2.4 T,|B|max in the outer

yoke, the field insidethis shielded region isa fraction of a Gauss.


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Plot of |B| (Tesla) for the Yoke and Two Layer Shield Structure

Insert Plot for |B| x104

0.28 Gauss 0.36 Gauss


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BES-III: Peak Field in IR Quad Coil*

ak

fieldca

lculation

is

lped

turn

bring

my

idea

tofr

uition.

15

Septe

mber2011


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*Pat Thompson is primary author of the codes, Wire2Dopt, WireEndOpt, FlatPatternGen,SerpentineGen, Coilfield, CoilPlot and CoilForce among with many other BNL codes.

This

BEPC-II

pe

one

way

Pat

h

cra

zy

Serpentine

B.Parke

r


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How far will we take BNL Direct Wind?How far will we take BNL Direct Wind?

ILC DID


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Adieu Pat.Adieu Pat.


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Extra Slides


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IR Configuration for eRHIC

eRHIC IR Magnets for HadronsDownstream (Electrons Upstream)

Critical magnets withrequirements coming

from both acceleratorand detector physics.

Electron beam

15 September 2011 eRHIC IR Magnet Designs,Brett Parker, BNL-SMD

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Look to bring e-beam to IP while keeping strong bends faraway (minimize Synrad related backgrounds).

Provide good experimental acceptance and separateneutrons and other off-momentum charged particles from theoutgoing hadron circulating beam.

rect on


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First IR Magnet Considerations

Must provide low-field region, 10 mr awayfrom hadron beam, for incoming e-beam.

Strong beam focusing + large solid angle

for detection superconducting magnet.

For compact optics solution with tailoreddeflection and separation of off-momentum No e 4.5 m *


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particles

use combined function magnet.

Above implies fairly high coil peak fields (at least

compared to iron saturation); how can we create a lowfield pocket for the e-beam to get to the IP?


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eRHIC Magnet 2D and 3D Field Profiles

3D Coil Pattern


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, ,

X Ranges from 22. to -0.67 mm, (Y=0 mm)

IP End

Non-IP End

Initial angle is -10. mr (w.r.t. electronbeam) and exit angle is -14.0 mr.

Average B is 1.73 T for4 mr added deflection

3D field is calculated viarescaling of the bare coilsusing the 2D results. For

final design we need fullcalculations and to optimizethe shielding to take intoaccount end-field effects.


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Summary of Integral Field Quality in ATF2 Magnet

ATF2Coils


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Harmonics are in "Units" of 10-4 of the main field at 25 mm as

seen from the lead ends of respective magnets (yieldingopposite sign of field angle in the two magnets). I.T.F forQuadrupole is in T/kA; ITF for Sextupole is in T/m/kA (Integralof B" in sextupole is two times the value reported for the I.T.F).


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ILC R&D Prototype and ATF2 Comparison

ATF2 Upgrade Magnet

Both are compatible with 1.9K testing via

an ILC-style Service Cryostat (SC) at BNL.

The ATF2 magnet can be tested with beam;

there is no way to beam test R&D prototype.


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(concept test with beam)

ILC QD0 Full-Length R&D Prototype Magnet Program(a full-scale, instrumented, 1.9K ILC SC, systems test)


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ILC 14 mr Crossing Angle Magnet Details

QD0 Coils in Opera3d

The QD0 magnet cryostat


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contains multiple activelyshielded quadrupole coils,

with sextupole and octupole

coils, many correction coils

plus an adjustable force-neutral anti-solenoid.

C t t b d di S ti t


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Constant bend radius Serpentine turnsfor integral harmonics identical to 2D


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Final SCB Serpentine Coil Pattern.


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BEPC-II Design Details


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HERA-II Cryostat Design Summary


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reallyThis ^is the last slide,

Adieu.

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Brrokshaven National Lab 4FO 6 Parker BNL Direct Wind Magnets