Development of Automatic Welding p gSystem for TPS Aluminium

Bending ChambersBending Chambers

C L Ch S N H C C Ch Y B Ch C Y Y C K K C KC L Chen, S N Hsu, C C Chang, Y B Chen, C Y Yang, C K Kuan, C K Chan, H P Hsueh, G Y Hsiung, J R Chen

June 11, 2008

OutlineIntroduction Motivation Auto-Weld System Experiment Setup Results

Outline

• Introduction– Basic parameters for the TPS storage ringg g– Layout of vacuum systems

• Motivation• Two Automatic Welding Systems

– Two-axis auto welding system– Arc robot

• Experimental Setup• Results and Discussion• ConclusionConclusion

IntroductionIntroduction Motivation Auto-Weld System Experiment Setup Results

Introduction

Basic Parameters for the TPS Storage Ring

Parameters Symbols Values

Beam Energy E 3.0 GeV

Maximum Beam Current I 400 mA

B di R di f Di l 7 2575Bending Radius of Dipole ρ 7.2575 m

Bending Angle θ 7.5°Critical Energy εc 8.25 keV

Circumference L 518 4mCircumferenceVacuum Pressure

LP

518.4m<1 nToor

IntroductionIntroduction Motivation Auto-Weld System Experiment Setup Results

Introduction

IG3

Layout of Vacuum systems for One cell (1/24)(Pumps, Gauges, Valves)

SGV2IG3 IG4

IG5IG6

B-Chamber: A6061T6

BPM1 BPM2 BPM3 BPM4

SGV1S3 S4 B1S5

B2BPM5

BPM6BPM7

TMP2 TMP3

IP1NEG1NEG2 IP2 IP3

TMP1

TMP4

TMP5 TMP6

NEG3NEG4

NEG5 IP4NEG6NEG7

IP5NEG8NEG9

IP6NEG10

IntroductionIntroduction Motivation Auto-Weld System Experiment Setup Results

Introduction

CrotchAbsorber

Bellows NEGIPAbsorber

BPM

Advantages of using aluminum alloy as B-chamber material:Advantages of using aluminum alloy as B chamber material:

1. Easy machine ability

2 Good thermal conductivity2. Good thermal conductivity

3. Low outgassing rate

4 Low residual radioactivity4. Low residual radioactivity

MotivationIntroduction Motivation Auto-Weld System Experiment Setup Results

Motivation

B Ch b T Pl tB-Chamber Top Plate

3892Welding Seam Positions

Top and Bottom Plates are assembled by TIG welding method.

Total 48 B-Chambers in TPS

B-Chamber Bottom Plate

Material: A6061T6

A L th 3892

Total 48 B-Chambers in TPS

Average hand welding length: 300mm

Total weld seams: 2700 by hand weldingAverage Length: 3892mm

Average Width: 605mm(max), 160mm(min)

Total weld seams: 2700 by hand welding

(including pumping ports)

MotivationIntroduction Motivation Auto-Weld System Experiment Setup Results

Motivation

T t ti TIG ldi t h b• Two new automatic TIG welding systems have been developed:– Two-axis auto welding systemTwo axis auto welding system– Arc welding Robot

• Advantages of automation:– Controllable input

• Welding current• Torch moving speedg p• Welding seam path• Filler feeding speed

– Longer welding length-reduce the welding junction numbers andLonger welding length-reduce the welding junction numbers and leakage possibility

– High throughput process

Automatic Welding SystemIntroduction Motivation Auto-Weld System Experiment Setup Results

Automatic Welding System

• Material Preparation– Oil-free CNC machining processg p– Chemical cleaning process

Oxide layer scraping process– Oxide layer scraping process• Welding Equipment

– AC mode TIG welding process• OTC Daihen 500P is used for weldingg

Welding PlatformsIntroduction Motivation Auto-Weld System Experiment Setup Results

Welding Platforms

Two-Axis Auto Welding Systemy– Rectangular arms are

sometimes called "Cartesian" b th ’ bbecause the arm’s axes can be described by using the X and Y coordinate system.

– One axis is used to control the chamber’s movement in X direction. The other one is todirection. The other one is to move the torch perpendicular the chamber moving axis in Y directiondirection.

Two-Axis Auto Welding SystemIntroduction Motivation Auto-Weld System Experiment Setup Results

Two Axis Auto Welding System

Th ldi h i h fill h i h– There are one welding torches with filler mechanisms on each side of vacuum chamber. These two opposite torches can be switched on to implement two welds on each side of an aluminium chamber simultaneously.

Arc Robot SystemIntroduction Motivation Auto-Weld System Experiment Setup Results

Arc Robot System

R b ldi ldi h i f d d ll d b• Robot welding means welding that is performed and controlled by robotic equipment.

• Similar to two-axis auto welding system, robot arc welding is designed of g y , g gusing the same welding configuration.

• The robot’s arm has six degrees of freedom.

Real-Time Monitor Measurement

Introduction Motivation Auto-Weld System Experiment Setup Results

MeasurementA l ti th l d d f ti it i t i• A real-time thermal and deformation monitoring system is established for the automatic welding system.

• In order to obtain the welding variations, it is necessary to monitor th th l d d f ti h f th h bthe thermal and deformation changes of the vacuum chamber.

Vertical dial gagesVertical dial gages

Horizontal dial gagesThermocouplesg g

Welding Test ExperimentIntroduction Motivation Auto-Weld System Experiment Setup Results

Welding Test Experiment

Name forY12

Y22Name for Vertical Dial GagesName for Horizontal

Test Chamber Dimensions

Straight Chamber T12

T13

T14

T24

Name for ThermocouplesDial Gages

X12

X13

X14

X24

Name for Horizontal Dial Gages

g

(1 meter) T11

T12

T21

T22

T23

Y11

X11

X12

X21

X22

X23

Vertical/Horizontal Dial Gage

Thermocouple

T21Y11

Y21

X21

Welding Test ExperimentIntroduction Motivation Auto-Weld System Experiment Setup Results

Welding Test Experiment

TIG Welding Conditions Welding System Used 2-axis auto welding system

TIG Machine Two AC TIG torches

Base Metal A6061Base Metal A6061

Filler A4043 φ3.2mm

Torch Type Pure Tungsten φ3.2mm

Start Current 140 A

Final Current 130 A

Welding Length 750 mmWelding Length 750 mm

Temperature Before Welding Room temperature

Welding Speed 180 mm/ming p

Sample Fixture Type Floating method

Ar Protection Flow Rate 10 l/min

H idit 50%Humidity 50%

Room Temperature 23ºC

Welding ResultsIntroduction Motivation Auto-Weld System Experiment Setup Results

Welding Results T e m p 1 1

T 1 2

1 0 0

1 2 0

1 4 0

1 6 0

re (C

)

T e m p 1 2 T e m p 1 3 T e m p 1 4 T e m p 2 1 T e m p 2 2 T e m p 2 3 T e m p 2 4

4 0

6 0

8 0

Tem

pera

tur

0 2 0 0 4 0 0 6 0 0 8 0 0 1 0 0 0 1 2 0 0 1 4 0 0 1 6 0 0 1 8 0 0 2 0 0 00

2 0

T i m e ( S e c o n d )

0 . 1 8 Y 1 1 Y 1 2Y 2 1

0 . 1 0

0 . 1 2

0 . 1 4

0 . 1 6

on (m

m)

Y 2 1 Y 2 2

0 . 0 2

0 . 0 4

0 . 0 6

0 . 0 8

Def

orm

atio

0 2 0 0 4 0 0 6 0 0 8 0 0 1 0 0 0 1 2 0 0 1 4 0 0 1 6 0 0 1 8 0 0 2 0 0 0- 0 . 0 2

0 . 0 0

T i m e ( s e c o n d s )

Welding ResultsIntroduction Motivation Auto-Weld System Experiment Setup Results

Welding Results T e m p 1 1

T 1 2

1 0 0

1 2 0

1 4 0

1 6 0

re (C

)

T e m p 1 2 T e m p 1 3 T e m p 1 4 T e m p 2 1 T e m p 2 2 T e m p 2 3 T e m p 2 4

4 0

6 0

8 0

Tem

pera

tur

0 2 0 0 4 0 0 6 0 0 8 0 0 1 0 0 0 1 2 0 0 1 4 0 0 1 6 0 0 1 8 0 0 2 0 0 00

2 0

T i m e ( S e c o n d ) X 1 1 X 1 2X 1 3

0 . 2 0

0 . 2 5

0 . 3 0

izon

tal (

mm

)

X 1 3 X 1 4 X 2 1 X 2 2 X 2 3 X 2 4

0 . 0 5

0 . 1 0

0 . 1 5

efor

mat

ion

in H

or

0 2 0 0 4 0 0 6 0 0 8 0 0 1 0 0 0 1 2 0 0 1 4 0 0 1 6 0 0 1 8 0 0 2 0 0 0

0 . 0 0

D

T i m e ( s e c o n d )

Temperature ComparisonIntroduction Motivation Auto-Weld System Experiment Setup Results

Temperature Comparison200

50

100

150

200

Tem

p (d

egre

e C)

Torch at T11

50

100

150

200

Tem

p (d

egre

e C)

Torch at T21

0T11 T12 T13 T14

100

150

200

(deg

ree C

)

Torch at T12

0T21 T22 T23 T24

100

150

200

(deg

ree C

)

Torch at T22

0

50

T11 T12 T13 T14

Tem

p

200

0

50

T21 T22 T23 T24

Tem

p ( Torch at T22

200

0

50

100

150

T11 T12 T13 T14

Tem

p (d

egre

e C)

Torch at T13

0

50

100

150

Tem

p (d

egre

e C)

Torch at T23

T11 T12 T13 T14

100

150

200

emp

(deg

ree C

)

Torch at T14

T21 T22 T23 T24

100

150

200em

p (d

egre

e C)

Torch at T24

0

50

T11 T12 T13 T14

Te

0

50

T21 T22 T23 T24

Te

ANSYS SimulationIntroduction Motivation Auto-Weld System Experiment Setup Results

ANSYS Simulation

Thermal and Deformation SimulationsThermal and Deformation Simulations

B-Chamber FabricationIntroduction Motivation Auto-Weld System Experiment Setup Results

B Chamber Fabrication

ConclusionIntroduction Motivation Auto-Weld System Experiment Setup Results

Conclusion

T t ti ldi t i t d d• Two automatic welding systems are introduced

• A test chamber was welded and leakage-free checked (<1×10-10 mbar·l/s )

• Thermal deformation is monitored, and the final deformation is acceptable (~0.15mm).

• This auto welding method provides a promise of welding TPS aluminium vacuum chambers.

Introduction Motivation Auto-Weld System Experiment Setup Results

Thanks for your attention!!