J.H. Chrzanowski Mod Coil R&D Update 1

Modular Coil R&D Keystone Activities

April 30, 2003James H. Chrzanowski

J.H. Chrzanowski Mod Coil R&D Update 2

Keystone Trials-

• The Keystone winding trials have begun.

• Initial measurement of winding surface was performed using “Faro” measuring arm.

• Bench top tests were performed

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FARO Arm Measurements

• Plot from Faro arm measurements• Have not compared with original Pro-E model

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Keystone Bench Top Tests

• Bench top tests were performed comparing the single copper conductor vs. 4-rope conductor

• Lengths of insulated [1 half lapped layer of dry glass only] copper rope specimens were wound onto a 3.5 inch diameter pipe

J.H. Chrzanowski Mod Coil R&D Update 5

Width 0.545

Height 0.660

Prior to Winding

B

A

D

C

0.520

0.650

0.690

0.660

After Winding

Height

Width A

B

CD

Single Conductor- Results of Bench Top Tests

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4-Rope Conductor- Results of Bench Top Tests

A

B

CDHeight

Width

Width 0.543

Height 0.670

Prior to Winding

B

A

D

C

0.540

0.620

0.577

0.750

After Winding

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4- Rope Conductor

Position 1 2 3 4 5 6

A .550 .533 .530 .540 .540 .545

B .640 .636 .630 .620 .645 .645

C .572 .597 .596 .577 .612 .610

D .723 .770 .770 .750 .740 .685

Position 5 10 15 20 25 30 35 40

Width .543 .540 .543 .540 .543 .543 .543 .543

Height .670 .670 .670 .668 .670 .670 .670 .670

After Winding

Prior to Winding

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Keystone Trials - 4 Rope Conductor

• Extreme distortion and twisting of the individual copper ropes

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Additional Issues

• Insulating the 4-rope conductor via the taping machine is extremely difficult

• Twisting and separation of the ropes causes inconsistent application of insulation

• The single conductor offers less of a challenge

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Keystone Trials-

• Forward progress was needed• Decision was made to use our

remaining 20 feet of single conductor to gain some preliminary Keystone data

• Single copper conductor was hand insulated with glass and Kapton, positioned onto the winding form and clamped in place

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Preliminary Keystone data

Wrapped-straight Laid/clamped into fixture Unclamped-bent to fixturemeasured w/calipers measured w/special measured w/calipers

Fixture column #

Location (inches) H W H W H W

29 42 668 764 643 667 75032 48 675 773 630 771 673 76436 54 660 760 659 67439 60 660 782 771 680 768

69 126 664 765 660 667 76371 132 650 767 669 77873 138 650 757 652 670 753

99 200 652 77 663 776 660 766102 206 661 771 691 746106 212 660 760 683 659 767109 218 652 764 808 658 773

One observation made is that varying the clamp pressure can result in a ~0.008" change in the measurement.

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Keystone Fixture Locations

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Preliminary Findings-• Preliminary Keystone R&D activities have shown that the

single conductor has many advantages over the 4-rope conductor.

• It was hoped that the 4-rope conductor would reduce keystoning. In fact the opposite is true.

• The conductors cannot slide to each other without causing extreme distortion.

• Using an automatic taping machine on the 4-rope conductor is a nightmare. Inconsistent layers plus loose conductors are all counterproductive

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Conductor Recommendation

• Seriously consider returning to single conductor as baseline plan for modular coils perhaps 34 ga instead of 36 ga

• Procure additional single copper rope conductor for completing the Keystone tests (Carm Hjelm from New England wire will have a quote to me by tomorrow. He expects delivery by approx. June 6th.)

• Use the 4-rope conductor for winding the demo(racetrack) coil– Hand insulate if necessary

• Use the 4-rope conductor for balance of specimens for CTD mechanical thermal tests.

• Prepare several single conductor specimens for comparison with 4-conductor test results

• Use single conductor for next major VPI of twisted tee