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Winding machines for the manufacturing of superconductive coils of the main European fusion research machines
Fusion Engineering and Design 75–79 (2005) 7–10
Winding machines for the manufacturing of superconductive coils of the main European fusion research machines Rodolfo Cazzaniga a,∗ , N. Valle b , C. D’Urzo b a b
TPA Brianza Soc. Coop., Via Garibaldi, 12, 23891 Barzan`o (LC), Italy Ansaldo Superconduttori ASG, Corso Perrone 73r, 16129 Genova, Italy Available online 26 July 2005
Abstract The successfull construction of large magnets passes through the development and application of non-conventional manufacturing processes. A difficult and delicate step in the manufacturing of superconducting coils is the conductor winding technique. It is often a challenging and technologically advanced process, developed according to the requirements of each project. An important aspect during the winding is to avoid any deformation of the cable cross section leading to a damage of the strands and to maintain the design features of the cable. A second aspect is to assure the suitable repeatability and a production rate for an industrial process. The winding line is a system of different machines linked and tuned together properly designed for each project. An adapted software assures the overall process control. TPA realized for ANSALDO Superconduttori the winding lines for many projects: TFMC (NET-TEAM), CMS (INFN-CERN), WENDELSTEIN W7-X (Max Planck Institute, IPP), etc. The experience acquired in this field by ANSALDO Superconduttori and by TPA (as manufacturing tools and equipments supplier) has been acknowledged by CERN with “The CMS Gold Award” of the Year 2004. The paper describes the main features of the winding lines, the main problems, the technical solutions used for the above mentioned projects and the new ideas for the forthcoming ones. © 2005 Elsevier B.V. All rights reserved. Keywords: Superconducting coil; Winding line; Project
1. Introduction TPA designed and built winding lines for the assembly of superconducting coils according to the manufac∗ Corresponding author. Tel.: +39 039 955169; fax: +39 039 9210409. E-mail address: [email protected] (R. Cazzaniga).
0920-3796/$ – see front matter © 2005 Elsevier B.V. All rights reserved. doi:10.1016/j.fusengdes.2005.06.055
turing technique developed by ANSALDO Superconduttori. Here, we describe the different winding techniques and winding lines, which have been realized for different customers: - Outer winding with inner form and controlled pulling force of the conductor
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R. Cazzaniga et al. / Fusion Engineering and Design 75–79 (2005) 7–10
Atlas B0 winding line Atlas BT winding line Revamping of the LHC winding device - Winding line with internal form and calendering on the conductor Tore Supra Iter TF Model Coil W7-X - Stress-free inner winding with outer form Finuda (INFN) Babar (INFN/SLAC, USA) CMS (INFN/CERN) - Stress-free winding without form MHD (CNR) New technical solutions have been developed for each project in order to satisfy the specific requirements of the customer. Usually, NC control system and feedback devices are used to control all the process. Research and development activities on the winding lines have been performed with ANSALDO Superconduttori in order to optimize the manufacturing sequence. A short description of the Tore Supra, Iter TF Model Coil and W7-X winding lines (used in the manufacturing of superconducting coils for fusion experiments) and the last realized winding line (CMS) are here reported.
Fig. 1. Tore Supra—winding stage with vertical pressing rolls.
- Hydrostatic supporting winding table with NC motor-driven - Roll pressing system of the winding - Winding form in AISI 316 Besides were designed and manufactured: - Additional equipment for toroids manufacturing - Welding equipment of the thick box (Fig. 1).
2. Tore Supra winding line Conductor dimensions 5.6 mm × 2.8 mm Winding characteristics First layer with 39 clockwise turns Inner diameter 2306 mm External diameter 2760 mm Second layer with 39 anticlockwise turns Inner diameter 2306 mm External diameter 2760 mm Winding line characteristics Winding line speed from 0 to 100 mm/s The supply included: - Unwinding reel - Straightening unit - Pre-calendering unit
3. Iter Model Coil winding line Conductor characteristics Diameter: 39.5 mm Material: external jacket “316LN” Winding characteristics No. 10 turns for each single pancake Radial-plate dimension about 3640 mm × 2600 mm Winding line characteristics - Unwinding reel (diameter of 2000 mm) - Pre-straightening unit - Straightening unit with motorized rollers - Cleaning and Sandblasting units (not TPA supply) - Winding unit consisting of: (a) Feeder with NC motorized rollers.
R. Cazzaniga et al. / Fusion Engineering and Design 75–79 (2005) 7–10
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Fig. 3. W7-X—clean area: winding reels on shaped die. Fig. 2. Iter Model Coil 3D drawing.
(b) NC calendering machine placed over the radialplate. (c) Winding table with NC roto-translating system and mechanical transmission with gap recovery device. (d) Control system of the conductor. Winding characteristics The ITER Model Coil winding is performed by lowering into the reaction mould the cable already bent at the nominal dimensions without any residual stress. To obtain this result, it has been necessary to perform the bending of the conductor at a radius smaller than the nominal value keeping into account the spring-back effect and the different developed length (Fig. 2) [2].
Winding pack overall dimensions Winding line characteristics The conductor preparation line mainly consists of Conductor reel carrier Straightening unit Cleaning unit (not TPA supply) Sandblasting device (not TPA supply) Turn insulation wrapping device Recovering reels
226 mm × 165.6 mm
The winding line mainly consists of Winding forms carrier Conductor reels Winding form tilting tables (Fig. 3) [1]
5. CMS winding line 4. W7-X winding line Conductor characteristics Jacket Jacket alloy Jacket external dimensions Inner hole Cable Diameter Strand type Winding characteristics No. 9 turns for 11 layers
The winding line was designed according to the principle of inner winding method. Al 6061 16 mm × 16 mm 12 mm 11.6 mm Copper–Nb/Ti filaments
Conductor characteristics 21.6 mm × 64 mm Al 6082 alloy with a pure Al matrix containing a 32 strands Rutherford cable coextruded inside Winding characteristics No. 109 turns for each layer No. 4 coaxial layers Winding form dimensions
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R. Cazzaniga et al. / Fusion Engineering and Design 75–79 (2005) 7–10
Inner diameter 6846 mm Height 2500 mm Winding line characteristics The winding line is placed at 8.5 m from the ground and it is mainly composed by: - Unwinding reel with a diameter of 2500 mm - Straightening unit with motorized rollers - NC milling machine for the conductor exits machining - Cleaning unit (not TPA supply) - NC calendering machine consisting of: (a) Feeder with NC motorized rollers (b) Pre-calendering unit (c) NC calendering unit - Control system of the conductor - Sandblasting units (not TPA supply) - Glass tape wrapping device - Motorized support conductor system during transferring - Sequential push conductor system - Winding table consisting of: (a) NC rotating table with hydrostatic support (b) Lifting system by screw jacks (load capacity 200 tonnes) (c) Hydraulic axial pressing system (load capacity 600 tonnes) (d) winding table movement is carried by means of air cushions (load capacity 400 tonnes). Operation characteristics The winding is performed by bending the conductor at a radius smaller than the nominal value.
Fig. 5. CMS 3D drawing—self-moving upper position.
After the transferring into the outer cylinder, the conductor is pressed against to the cylinder wall by the sequential pushing conductor system in order to guarantee a winding without radial gap. Finally by using the axial pressing steps (performed during the winding) it is possible to guarantee the nominal height of the turn layers (Figs. 4 and 5) [3].
Acknowledgments The authors wish to thank the members of the Institutes (INFN, CERN, NET, EFDA, IPP) for their support on this work. The useful discussion with them is greatly acknowledged.
References [1] L. Wegener, J.-H. Feist, J. Sapper, F. Kerl, F. Werner, et al., Final design and construction of the Wendelstein 7-X coils, 21st SOFT, Madrid, Spain, September 11–15, 2000. [2] R.K. Maix, H. Fillunger, F. Hurd, E. Salpietra, N. Mitchell, P. Libeyre, et al., Completion of the ITER toroidal field model coil, 21st SOFT, Madrid, Spain, September 11–15, 2000. [3] P. Fabbricatore, The winding line for the CMS reinforced conductor, 17th MT, Geneva, September 24–28, 2001. Fig. 4. CMS 3D drawing—self-moving lower position.
Winding machines for the manufacturing of superconductive coils of the main European fusion research machines Rodolfo Cazzaniga a,∗ , N. Valle b , C. D’Urzo b a b
TPA Brianza Soc. Coop., Via Garibaldi, 12, 23891 Barzan`o (LC), Italy Ansaldo Superconduttori ASG, Corso Perrone 73r, 16129 Genova, Italy Available online 26 July 2005
Abstract The successfull construction of large magnets passes through the development and application of non-conventional manufacturing processes. A difficult and delicate step in the manufacturing of superconducting coils is the conductor winding technique. It is often a challenging and technologically advanced process, developed according to the requirements of each project. An important aspect during the winding is to avoid any deformation of the cable cross section leading to a damage of the strands and to maintain the design features of the cable. A second aspect is to assure the suitable repeatability and a production rate for an industrial process. The winding line is a system of different machines linked and tuned together properly designed for each project. An adapted software assures the overall process control. TPA realized for ANSALDO Superconduttori the winding lines for many projects: TFMC (NET-TEAM), CMS (INFN-CERN), WENDELSTEIN W7-X (Max Planck Institute, IPP), etc. The experience acquired in this field by ANSALDO Superconduttori and by TPA (as manufacturing tools and equipments supplier) has been acknowledged by CERN with “The CMS Gold Award” of the Year 2004. The paper describes the main features of the winding lines, the main problems, the technical solutions used for the above mentioned projects and the new ideas for the forthcoming ones. © 2005 Elsevier B.V. All rights reserved. Keywords: Superconducting coil; Winding line; Project
1. Introduction TPA designed and built winding lines for the assembly of superconducting coils according to the manufac∗ Corresponding author. Tel.: +39 039 955169; fax: +39 039 9210409. E-mail address: [email protected] (R. Cazzaniga).
0920-3796/$ – see front matter © 2005 Elsevier B.V. All rights reserved. doi:10.1016/j.fusengdes.2005.06.055
turing technique developed by ANSALDO Superconduttori. Here, we describe the different winding techniques and winding lines, which have been realized for different customers: - Outer winding with inner form and controlled pulling force of the conductor
8
R. Cazzaniga et al. / Fusion Engineering and Design 75–79 (2005) 7–10
Atlas B0 winding line Atlas BT winding line Revamping of the LHC winding device - Winding line with internal form and calendering on the conductor Tore Supra Iter TF Model Coil W7-X - Stress-free inner winding with outer form Finuda (INFN) Babar (INFN/SLAC, USA) CMS (INFN/CERN) - Stress-free winding without form MHD (CNR) New technical solutions have been developed for each project in order to satisfy the specific requirements of the customer. Usually, NC control system and feedback devices are used to control all the process. Research and development activities on the winding lines have been performed with ANSALDO Superconduttori in order to optimize the manufacturing sequence. A short description of the Tore Supra, Iter TF Model Coil and W7-X winding lines (used in the manufacturing of superconducting coils for fusion experiments) and the last realized winding line (CMS) are here reported.
Fig. 1. Tore Supra—winding stage with vertical pressing rolls.
- Hydrostatic supporting winding table with NC motor-driven - Roll pressing system of the winding - Winding form in AISI 316 Besides were designed and manufactured: - Additional equipment for toroids manufacturing - Welding equipment of the thick box (Fig. 1).
2. Tore Supra winding line Conductor dimensions 5.6 mm × 2.8 mm Winding characteristics First layer with 39 clockwise turns Inner diameter 2306 mm External diameter 2760 mm Second layer with 39 anticlockwise turns Inner diameter 2306 mm External diameter 2760 mm Winding line characteristics Winding line speed from 0 to 100 mm/s The supply included: - Unwinding reel - Straightening unit - Pre-calendering unit
3. Iter Model Coil winding line Conductor characteristics Diameter: 39.5 mm Material: external jacket “316LN” Winding characteristics No. 10 turns for each single pancake Radial-plate dimension about 3640 mm × 2600 mm Winding line characteristics - Unwinding reel (diameter of 2000 mm) - Pre-straightening unit - Straightening unit with motorized rollers - Cleaning and Sandblasting units (not TPA supply) - Winding unit consisting of: (a) Feeder with NC motorized rollers.
R. Cazzaniga et al. / Fusion Engineering and Design 75–79 (2005) 7–10
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Fig. 3. W7-X—clean area: winding reels on shaped die. Fig. 2. Iter Model Coil 3D drawing.
(b) NC calendering machine placed over the radialplate. (c) Winding table with NC roto-translating system and mechanical transmission with gap recovery device. (d) Control system of the conductor. Winding characteristics The ITER Model Coil winding is performed by lowering into the reaction mould the cable already bent at the nominal dimensions without any residual stress. To obtain this result, it has been necessary to perform the bending of the conductor at a radius smaller than the nominal value keeping into account the spring-back effect and the different developed length (Fig. 2) [2].
Winding pack overall dimensions Winding line characteristics The conductor preparation line mainly consists of Conductor reel carrier Straightening unit Cleaning unit (not TPA supply) Sandblasting device (not TPA supply) Turn insulation wrapping device Recovering reels
226 mm × 165.6 mm
The winding line mainly consists of Winding forms carrier Conductor reels Winding form tilting tables (Fig. 3) [1]
5. CMS winding line 4. W7-X winding line Conductor characteristics Jacket Jacket alloy Jacket external dimensions Inner hole Cable Diameter Strand type Winding characteristics No. 9 turns for 11 layers
The winding line was designed according to the principle of inner winding method. Al 6061 16 mm × 16 mm 12 mm 11.6 mm Copper–Nb/Ti filaments
Conductor characteristics 21.6 mm × 64 mm Al 6082 alloy with a pure Al matrix containing a 32 strands Rutherford cable coextruded inside Winding characteristics No. 109 turns for each layer No. 4 coaxial layers Winding form dimensions
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R. Cazzaniga et al. / Fusion Engineering and Design 75–79 (2005) 7–10
Inner diameter 6846 mm Height 2500 mm Winding line characteristics The winding line is placed at 8.5 m from the ground and it is mainly composed by: - Unwinding reel with a diameter of 2500 mm - Straightening unit with motorized rollers - NC milling machine for the conductor exits machining - Cleaning unit (not TPA supply) - NC calendering machine consisting of: (a) Feeder with NC motorized rollers (b) Pre-calendering unit (c) NC calendering unit - Control system of the conductor - Sandblasting units (not TPA supply) - Glass tape wrapping device - Motorized support conductor system during transferring - Sequential push conductor system - Winding table consisting of: (a) NC rotating table with hydrostatic support (b) Lifting system by screw jacks (load capacity 200 tonnes) (c) Hydraulic axial pressing system (load capacity 600 tonnes) (d) winding table movement is carried by means of air cushions (load capacity 400 tonnes). Operation characteristics The winding is performed by bending the conductor at a radius smaller than the nominal value.
Fig. 5. CMS 3D drawing—self-moving upper position.
After the transferring into the outer cylinder, the conductor is pressed against to the cylinder wall by the sequential pushing conductor system in order to guarantee a winding without radial gap. Finally by using the axial pressing steps (performed during the winding) it is possible to guarantee the nominal height of the turn layers (Figs. 4 and 5) [3].
Acknowledgments The authors wish to thank the members of the Institutes (INFN, CERN, NET, EFDA, IPP) for their support on this work. The useful discussion with them is greatly acknowledged.
References [1] L. Wegener, J.-H. Feist, J. Sapper, F. Kerl, F. Werner, et al., Final design and construction of the Wendelstein 7-X coils, 21st SOFT, Madrid, Spain, September 11–15, 2000. [2] R.K. Maix, H. Fillunger, F. Hurd, E. Salpietra, N. Mitchell, P. Libeyre, et al., Completion of the ITER toroidal field model coil, 21st SOFT, Madrid, Spain, September 11–15, 2000. [3] P. Fabbricatore, The winding line for the CMS reinforced conductor, 17th MT, Geneva, September 24–28, 2001. Fig. 4. CMS 3D drawing—self-moving lower position.