Engi

neer

ing

Depa

rtm

entEN Status of TCSP manufacturing

Collimation Working Group (CWG)24 June 2013

A. Dallocchio, A. Bertarelli, F. Carra, L. Gentini, P. Francon, P. Moyret

On behalf of the TCTP/TCSP design, prototyping and manufacturing team

Engi

neer

ing

Depa

rtm

entEN

A. Dallocchio – EN-MME 2

MME deliverable

Status of sub-assemblies production: Movable table

Vacuum tank

Jaw assembly

RF system

BPM cables

Future planning

Outlook

24 June 2013

Engi

neer

ing

Depa

rtm

entEN

A. Dallocchio – EN-MME 3

Deliverables

24 June 2013

Tank

Jaw assemblyMovable table

EN/MME to provide EN/STI with 3 TCSP collimators (2 + 1 spare) inside a welded tank (same deliverable as CERCA during Phase I production); STI to prepare collimators for installation.

Engi

neer

ing

Depa

rtm

entEN

A. Dallocchio – EN-MME 4

Movable table

24 June 2013

All tables (6x) available and assembled

Several Tests performed on a (7th) prototype table on test-bench: 1st complete Lifecycle endurance test

(15’000 standard cycles) @ -135˚ Torque measurement every 5k

cycles Back-driving tests in all orientations

without motors 3 months inactivity 2nd complete Lifecycle endurance test

(15’000 standard cycles) @ -135˚ Torque measurement every 5k

cycles Back-driving tests in all orientations

without motors

Surface analysis of bearing shafts after 2 lifecycle tests, EDMS 1136770

Tests passed !!!

Engi

neer

ing

Depa

rtm

entEN

A. Dallocchio – EN-MME 5

Vacuum tank

24 June 2013

All tanks (3x) assembled and available; cover to be welded after jaw installation.

Leak tests performed to assess the vacuum tightness of weldings and bellows.

Pressure tests performed on vacuum tank cooling circuits as prescribed on manufacturing drawings (30 bars pressure test).

Tests passed !!!

Engi

neer

ing

Depa

rtm

entEN

A. Dallocchio – EN-MME 6

Jaw assembly

24 June 2013

All jaws (6x) assembled Components cleaned following prescribed procedures

as specified on drawings: Cooling pipes, EMDS n. 1210658 Stainless steel, EDMS n. 1210660 Glidcop, EDMS n. 1210661 Copper-Beryllium RF contacts, EDMS n. 1210662

CFC Jaws recovered from Phase I production, re-machined to fit TCSP taperings (Firing procedure 2hours @ 1000˚C performed again)

Metrology measurements validate flatness requirements on all TCSP jaws, EDMS n. 1275108

Outgassing test performed on one TCSP jaw without ferrite. Document under preparation by G. Cattenoz.

BPM positioning with respect to active jaw surface within 0.05 mm of tolerance (as specified on drawings)

Pressure tests of cooling pipes 50 bar (20 minutes)

0

10

20

30

40

50

60

70

Jaw 1 Jaw 2 Jaw 3 Jaw 4 Jaw 5 Jaw 6

Jaw

Fla

tnes

s (m

icro

n)

Tests passed

TE-VSC to formally confirm

Engi

neer

ing

Depa

rtm

entEN

A. Dallocchio – EN-MME 7

Jaw assembly – conductance tests

24 June 2013

Conductance tests performed by I. Leitao in order to assess quality of jaw brazing . Acceptance value 7000 W/m2/K (average value over jaw length). All the 6 jaws are accepted.

Conductance tests of TCSP jaws – courtesy of I. Leitao

Tests passed !!!

Engi

neer

ing

Depa

rtm

entEN

A. Dallocchio – EN-MME 8

RF system

24 June 2013

Thermal treatment procedure developed by TE/VSC and EN/MME: 1000 ˚C, 48h in air + 48h under vacuum; EDMS document 1276976

Firing of 5 ferrite batches already performed (for 3 TCSP + 1 TCTP proto + 1 TCSM proto)

Material for ferrite housing and EM shielding: 316 LN (no CrO coating) Maximum temperature accepted on ferrite: 100 ˚C (imposed by UHV requirements) BE/ABP team to confirm the RF-induced losses in operation (end of June?) RF contacts for end transitions same as Phase I

RF system conform to UHV requirements

BE/ABP inputs to be confirmed

Engi

neer

ing

Depa

rtm

entEN

A. Dallocchio – EN-MME 9

BPM cables

24 June 2013

First BPM batch received in 2010; leak tight cables (4 out of 6) used for endurance test on table test bench, to be then re-used for TCSM prototype

16 pre-series TCTP cables received in July 2012 available for 1 proto and 3 series units

Delivery of TCSP cables still pending; expected by 28th June

Outgassing test strategy for TCSP: 8 cables in one test run;(initial strategy: 4 cables in one test run, to be increased in case of positive results on the first batches)

Engi

neer

ing

Depa

rtm

entEN

A. Dallocchio – EN-MME 10

Action list to complete TCSP assembly

24 June 2013

1. BPM cables receptionI. Measurements of the height of shafts shoulder for the positioning of the jaw into the tank (done)II. BPM cables electrical tests (C. Boccard)III. BPM cables outgassing tests (G. Cattenoz)

2. Collimator assemblingI. BPM cables assembling on jaws II. Assembling of RF contacts on the top and bottom of the tankIII. Assembling of jaws inside the tank and connection of BPM and T cables on the flanges; assembling of

flanges + seals3. Measurements and tests on assembled collimator

I. Regulation of end stops and micro switches on 3D machineII. Control of position and flatness tolerances of jaws inside the tankIII. Torque test IV. BPM test with antenna (C. Boccard)

4. Further actions before tank closure:1. Welding of vacuum caps on the axes 2. Positioning of tank cover3. Torque test before tank welding

5. Tank cover EB welding6. Tests after welding:

I. Leak testII. Outgassing test

7. Delivery to EN/STI; RF contacts in the transitions + limit switch to be assembled by STI 

Engi

neer

ing

Depa

rtm

entEN

A. Dallocchio – EN-MME 11

Time schedule

24 June 2013

Delivery of BPM cables by end of June?

After cables reception, at least 10 days needed for electrical + outgassing tests

MME activities (listed in previous slide) take about 4 weeks per collimator

Assembly period right in the middle of summer holidays for most key players!

6 weeks needed by STI to prepare each TCSP for installation

Optimization of the planning will be performed once BPM cables delivery is confirmed

Engi

neer

ing

Depa

rtm

entEN

Thank you for your attention!