1 thermal tests planning for mock-up tm0 thermal tests planning for clic prototype module type 0...

[email protected]

1 Thermal tests planning for mock-up TM0

[email protected]

Thermal tests planning for CLIC prototype module type 0

July 17, 2012

F. Rossi

[email protected]


INTRODUCTION: CLIC prototype modules

1) Currently under assembly and installation

2) Main components under procurement

3) Last module

TM1 TM0 TM0 TM4

[email protected]



Prototype modules in LAB

Prototype modules in CLEX

Demonstration of the two-beam module designThis implies the assembly and integration of all components and technical systems, such as RF, magnet, vacuum, alignment and stabilization, in the very compact 2-m long two-beam module

Demonstration of the two-beam acceleration with two-beam modules in CLEXAddress other feasibility issues in an integrated approachIndustrialization and mass production study

2010-2014

[email protected]



• Assembly and integration of all technical systems (dummy RF structures and quadrupoles can be used – real dead weight and interfaces to other systems)

• Validation of different types of girders and movers• Full metrology of the module components• Pre-alignment of girders and RF structures on girders in the module environment,

including fiducialisation• Validation of interconnections and vacuum system • Stabilization of main beam quad in the module environment• Vibration study of all systems and identification of vibration sources• Measurement of resonant frequencies (both in lab and in the tunnel/underground

area)• Simulation of several thermal cycles: measurements of thermal transients (e.g. how

long it takes to achieve a new equilibrium state), fiducialisation verification• Transport of the module and verification of alignment

[email protected]


Experimental program for thermal tests

HEATING

No active heating in RF structures

COOLING

No active cooling in RF structures

MEASUREMENTS

1. Temperature

2. Alignment• Laser tracker• Romer arm• WPS• Micro-Triangulation

system

STEP 1 – Heating environment

ENVIRONMENT

Tamb = 20 - 40 °Cin steady-state conditions and by steps of 5 °C

HEATING

PETSby steps up to 110 W/unit

COOLING

PETS< max calculated T

MEASUREMENTS

1. Temperature

2. Volumetric flow rate


system

STEP 2 – Heating only PETS

ENVIRONMENT

Tamb = 20 °Cin steady-state conditions

HEATING

ASby steps up to 400 W/unit

COOLING

AS< max calculated T

MEASUREMENTS

1. Temperature



system

STEP 3 – Heating only AS

ENVIRONMENT

Tamb = 20 °Cin steady-state conditions

HEATING

AS + PETS + DBQby steps up to max power/unit

COOLING

AS + PETS + DBQ< max calculated T

MEASUREMENTS

1. Temperature



system

STEP 4 – Heating all module

ENVIRONMENT

Tamb = 20 - 40 °Cin steady-state conditions and by steps of 5 °C

G. Riddone, A. Samoshkin, CLIC Test Module meeting 25.07.2011

MEASUREMENTS

a. Comparison between laser tracker and WPS measurements (no movements of girders)

b. Alignment tests by moving girders via actuators and comparison between laser tracker and WPS measurements

STEP 0 – Alignment tests

ENVIRONMENT

Tamb = 20 & 40 °C

ALL THE TESTS ARE PERFORMED WITH NO VACUUM

[email protected]


TOPICS

Topics and updates concerning the status of:

1. CLIC prototype module type 0

2. Laboratory environment (air conditioning, ventilation, etc. )

3. Heating system (heaters, temperature sensors, etc.)

4. Cooling system (water supply, inlet/outlet cooling circuits, control valves, etc.)

5. Numerical simulations

6. Measurements

[email protected]


1. CLIC MODULESCLIC module type 1

Constraints for CLIC module type 1

[email protected]


1. CLIC PROTOTYPE MODULE TYPE 0

Cooling circuit

Vacuum flange

RF flange

Manifold

Interconnection flange

RF waveguide

Accelerating structure (AS)Super-accelerating

structure (SAS)

Test Module type 0 (TM0)

D. Gudkov

Tolerance Mock-up Real

Dext ± 4 μm ± 2.5 μm

Ra 0.4 μm 0.025 μm

Flatness 10 μm 1 μm

[email protected]



Brazing of 1st stack

Fiducialisation

EBW of 2 stacks

Brazing of 2nd stack

Fiducialisation

TIG welding of vacuum flanges

W36

W37

Installation on girders

W38

EBW tooling manufactured by COMEB

[email protected]



Real super-AS for CLEX

• CLIC prototype module type 1 will be also used to test real RF structures:

o 1 super-AS having real RF geometry

o PETS on-off mechanism

• These tests are necessary to validate current assembly procedures developed for mock-ups as well as to check current alignment requirements

• Real RF structures used for TM1 can be also used for RF tests in CLEX

PETS on-off mechanism

[email protected]


2. LABORATORY ENVIRONMENT

• Lab dimensions (169-S-039): 17 x 6 x 3 m

• Current annual temperature excursion: 17 - 27 °C

• Required: environmental temperature for Lab - adjustable range 20 - 40 °C

• Max temperature inside module: o MB: 43 °Co DB: 34 °C

Temperature field inside module(SAS = 820 W, PETS unit = 78 W, Tamb = 25 °C)

[email protected]



VEN

TILA

TIO

NSUPPLY

20 - 40 °C

T ± 0.5 °C

T ± 1 °C

• Preliminary meeting to define basic operating conditions:

o Adjustable temperature range: 20 – 40 °C (by steps of 5 °C)

o Humidity: “the relative humidity will not be regulated”, CLIC CDR Chapter 6, Civil engineering and technical services

o Air flow speed ( = 45000 m3/h -> v = 0.7 m/s), CLIC CDR Chapter 6, Civil engineering and technical services, page 523

o Low air flow on wires for alignment

o Boundary conditions coming from transportation tests (D. Gudkov)

SUPPLY

[email protected]



VEN

TILA

TIO

NT = 20 - 40 °C

VEN

TILA

TIO

N

T = 20 - 40 °C

PREVIOUS CONFIGURATION MODIFIED CONFIGURATION

SUPPLY SUPPLY SUPPLY SUPPLY

[email protected]



Boundary conditions:

• laser tracker position

• inlet/outlet assembly of hydraulic circuit

• transport test

HVAC for thermal test on CLIC prototype modules in building 169

transport test

inlet/outlet assembly

http://indico.cern.ch/getFile.py/access?contribId=3&resId=0&materialId=slides&confId=166049

[email protected]


3. HEATING SYSTEM: heaters

• Experimental conditions to be reproduced:G. Riddone, A. Samoshkin, CLIC Test Module meeting 25.07.2011

All heaters are currently stored in the lab

HEATERS

ASP = 3050 WV = 240 VI = P/V = 12.7 A

2 PETS UNITSP = 2*480 = 960 WV = 240 VI = P/V = 4 A

2 DBQP = 2*1600 W = 3200 WV = 240 VI = P/V = 13.3 A

AS + 2 PETS UNIT + 2 DBQI = 30 A

[email protected]


3. HEATING SYSTEM: temperature sensors

solid state relay

temperature sensors

heaters

ILHardware thermal

interlock (2 for AS, 1 for each PETS and DBQ)

max. temp. limit: 50 °C

All temperature sensors are currently stored in the lab

1 DOF for each heating sub-

system (AS, PETS and DBQ)

[email protected]


3. HEATING SYSTEM: air temperature

2 m

1.2 m

1 m

1.3 m

• 5 thermocouples for each section

• 15 thermocouples in total

• Continuous acquisition during tests

NI 921316-Channel Thermocouple Input Module

[email protected]


3. HEATING SYSTEM: softwareI. Kossyvakis, CLIC Test Module meeting 02.11.2011

Software interface

Panel for control valves

• The acquisition process is fully automatized and in principle no human intervention is necessary

[email protected]


4. COOLING SYSTEM

•Demineralized water

•Nominal volumetric flow rate: 0.36 m3/h

•Water inlet temperature: 25 °C

•Water outlet temperature: ~45 °C

•Max. pressure allowed: 5 bar

•Inlet/outlet interface

•Water supply

[email protected]


4. COOLING SYSTEM: AS

TS7

TS1 TS2

TS6

TS4

[email protected]


4. COOLING SYSTEM: PETS

TS17

TS22

TS23

TS24

TS25

TS26

[email protected]


4. COOLING SYSTEM: control valves

1. Delivered to Lab

2. Electric scheme under design

[email protected]


4. COOLING SYSTEM: water supply

Water pump

Heat exchanger

Temperature regulator

Inlet/outlet port

Water tank

• Water supply delivered to Lab and tested -> OK

• Max. pressure: 5 bar

• Responsible: F. Rossi (S. Lebet)

POWER SOCKETMax. 16 A


air cooling

[email protected]


4. COOLING SYSTEM: electric networks

AS heaterPETS heater

DBQ heaters

Temperature sensors (q.ty 29)CONNECTORS PANEL #2 for:• Control valves (q.ty 7)• Flow transducer (q.ty 1)• Pressure sensor (q.ty 1)

Supporting system for:• Control valves (q.ty 7)• Flow transducer (q.ty 1)• Pressure sensor (q.ty 1)

CONNECTORS PANEL #1 for:• Temperature sensors (q.ty 29)• Solid state relay systems for heaters (q.ty 3)

• Electric scheme for control valves, heaters, temperature sensors, etc. under design (J. Blanc)

CUPBOARD for:• NI cDAQ-9178 8 slots (q.ty 1)• NI cDAQ-9174 4 slots (q.ty 1)• Solid state relay devices (q.ty 3)• 24 V supply• Digital control electronics for proportional valves (q.ty 7)



• Improvement of current electric network of Lab in progress

[email protected]


5. NUMERICAL SIMULATIONS

Deformed shape of prototype module type 0 due to applied thermal RF loads (values in

µm)

Displacements [m](location and load type)

Prototype type 0

MB (RF load) 183DB (RF load) 47MB (vacuum load) 30DB (vacuum load) 131MB (gravity load) 27DB (gravity load) 40

Resulting displacements on the DB and MB lines due to thermal, vacuum and

gravity loads

Temperature [°C] Prototype type 0

Max temp. of module 43Water output temp. MB 35Water output temp. DB 30

Resulting temperatures inside the modules

R. Raatikainen

(SAS = 820 W, PETS unit = 78 W, Tamb = 25 °C)

[email protected]


6. MEASUREMENTS

Measuring arm Romer Multi Gage• With a length of 60 cm, this kind

of portable CMM allows to measure fiducials by probing or by one point. According to Romer, the maximum permissible error is less than 18 µm.

Laser tracker Leica AT401• According to simulation calculations, the

expected accuracy of AT401 measurements on a girder and its components is about 5 µm rms (up to 40 °C).

• Fiducials are measured with respect to a fixed reference system.

• Measurements taken from different stations can be elaborated and combined together.

• The measuring device must be at the same temperature of the parts to be measured.

Micro-Triangulation system• The principle of Micro-

Triangulation is to use the full potential of a theodolite by substituting a CCD camera instead of the eye of an operator.

• This method has clearly demonstrated its high precision capability on the 2 m long mock-up where a precision about 10 µm along each axis has been obtained in the determination of the illuminated fiducials locations.

Fiducials dedicated to Micro-triangulationThe aluminium main part of this fiducial (made in CERN) is equipped with a breakthrough ceramic ball with a diameter of 8 mm, a removable drawer which contain a LED allows to illuminate the accurate ball.

S. Griffet et al.

WPS system

[email protected]


CONCLUSIONS: THERMAL TESTS STRATEGY

NAME LAB CONFIGURATIONPARAMETERS

Heating Cooling Vacuum

TT1 TM0 V V X

TT2 TM0 + TM0 V V X

TT3 TM1 + TM0 V V V

TT2

TT3

[email protected]


CONCLUSIONS: schedule

• Presentation at the project meeting (September 2012)

• Review following the thermal tests on TM0 (Q2, 2013)

1 thermal tests planning for mock-up tm0 thermal tests planning for clic prototype module type 0...

Documents