Introduction to DS Coil Designs for MOLLER Spectrometer
The design process of downstream coils for the MOLLER Spectrometer, using the Pugh Matrix for decision-making. Details include coil engineering goals, conductor sizes, and the collaborative design process. Learn how to utilize the Pugh Matrix as a team effort to evaluate critical-to-quality requirements and alternative designs.
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MOLLER Spectrometer MOLLER Spectrometer Downstream Coil Design Down Select - The Process R. Fair v1.00 12.02.20 First Release (with support from the JLab Magnet Group, J. Mammei, K. Kumar and others)
Introduction to the two DS coil designs How do we use the Pugh Matrix? Extract from the matrix for the coil down select What happens next .?
Introduction to the two DS coil designs DS Hybrid Torus: Co-wound coils DS Segmented Torus: Independent coils
Coil Engineering - Process Choose appropriate design goals [1] Current density: 20 A/mm2 Water Flow Velocity: 15 ft/sec Water temperature rise: 35 oC ( note coolant supply 30 oC) Choose a operating differential pressure 100 psid (chosen to allow increase if needed to create flow but not limiting fitting or hose type choice) Nominal Current (Ampere Turns) by zone provided by collaboration) [1] Based on review of water-cooled magnets at JLab and SLAC Magnet type US Zone 1 Zone 2 Zone 3 Zone 4 Hybrid 5358 7752 10602 16862 29160 Segmented (15% More than Hybrid DS coil) 5358 8914 12192 19391 33534 Design current is 110% of nominal value provided by the collaboration Choose a conductor size (H x W x dia) for each coil type and create wind-able design to match collaboration requested current placement geometry and to clear particle tracks Provide simplified (blocky model) of winding layout to collaboration for evaluation of particle tracking Spectrometer Engineering and Design 4
What is a Pugh Matrix ? 1. It is a framework which formalizes decision-making 2. It allows us to identify the strengths and weaknesses of one solution compared to another 3. It also allows us to record how we made the decision 4. It works best when the whole team participates
How do we use the Pugh Matrix this MUST be a team effort 1. Enter Critical to Quality (CTQs) requirements For the Moller spectrometer, the main requirement (obviously) is being able to perform the physics This top level requirement can be broken down further to include the engineering requirements. We have divided it into DESIGN, FABRICATION, ASSEMBLY and OPERATION 2. Give each CTQ a weight i.e. ask ourselves how important is each CTQ to satisfying the physics requirements? The weights are usually rated from 1 to 10. 3. Rate each alternative design as better (1), worse (-1) or the same (0) as the baseline design . Here we have selected the baseline design to be the Hybrid coil design and the segmented coil design as the alternative
Extract from the Pugh Matrix for the coil design down select X
Extract from the Pugh Matrix for the coil design down select
Extract from the Pugh Matrix for the coil design down select
What happens next.? All team members to review the Pugh Matrix Excel Worksheet (in particular the weights) by Friday 4th Dec Friday 4th Dec detailed review of the Pugh Matrix make the down select Write a report summarizing the decision Ruben, Juliette, KK Convene the Change Control Board (by 12.15.20 ?) Jim Fast Present and defend the decision Ruben, Juliette, KK Formalize the decision Jim Fast
Subsystem Overview UPSTREAM DOWNSTREAM Extent of Spectrometer Scope + beam pipes to the dump Lead Collar Hybrid Lead Wall Lead Collar Scattering Chamber and Target (not included in Spectrometer scope) Primary beam window Lead Collar Shield Pipes Drift Pipe Detector Pipe Drift Pipe Electron beam Target Lead Wall Detectors (Not included in Spectrometer scope) 1.03.06 Blockers #6 and #7 (for calibration andbackground checks) 1.03.06 Collimator #4 (Secondary acceptance defining collimator) 1.03.07 Downstream Beam Pipes and Windows 1.03.02 Downstream Torus (Focusing and separation of particles) 1.03.06 Collimator #1 (Primary beam intercepting collimator) 1.03.03 Upstream Torus (Pre-bending of particles) Not shown here: 1.03.04 Field measurement system 1.03.05 Water chiller 1.03.08 Shielding supports 1.03.06 Collimator #5 (Photon-blocking collimator) and Lintels 1.03.06 Collimator #2 (Primary acceptance defining collimator) [Note: There is no Collimator #3] WBS 1.03 Spectrometer 12
BACKUP Coil Hydraulic and Electrical Design O:\Magnet_Design_Tools\Magnet Projects\MOLLER - Hall A\6. Engineering Calculations-Analyses-Simulations\Mechanical\Coil DP calcs Filename: CDT 110percent - Sept 2020 100psi w_KPP Seg SC 4.xls Worksheet: Release Sheet_V2
Ver y good </ = 15 25 12 Desi gn Goal OK </ = 20 35 15 UPSTREAM Too Hi gh > 30 45 20 Hi gh</ = 30 45 20 Cur r ent densi t y Tem per at ur e r i se W at er vel oci t y Upstream Torus v2-6b Goal DP Total NI Number of turns LUVATA Conductor # Conductor width Conductor width Conductor hole dia Insulated Coil Clearance to envelope Current Density Temperature rise Water velocity Water Pressure Drop Subcoil String flow rate Voltage Subcoil String (PS voltage) Current Subcoil String (PS current) Power Subcoil String (PS power) V2- U1 Upstream Torus v2-6c Goal DP Total NI Number of turns LUVATA Conductor # Conductor width Conductor width Conductor hole dia Insulated Coil Clearance to envelope Current Density Temperature rise Water velocity Water Pressure Drop Subcoil String flow rate Voltage Subcoil String (PS voltage) Current Subcoil String (PS current) Power Subcoil String (PS power) 100% 100 5357. 5 100% 100 5357. 5 5 6 6842 6842 W H d C mm mm mm mm A/mm2 C ft/sec psi gpm V A kW 9 9 W H d C mm mm mm mm A/mm2 C ft/sec psi gpm V A kW 9 9 5. 7 1. 7 5. 7 1. 7 19.6 24.1 11.1 16.3 22.1 10.0 100. 0 DT V DP F V I P DT V DP F V I P 99. 9 9. 6 54. 4 8. 7 54. 2 892. 9 48. 4 1071. 5 58. 3
Ver y good </ = 15 25 12 Desi gn Goal OK </ = 20 35 15 Too Hi gh > 30 45 20 Hi gh</ = 30 45 20 HYBRID DS Cur r ent densi t y Tem per at ur e r i se W at er vel oci t y Hybrid SC1(1.02) Goal DP Total NI Number of turns LUVATA Conductor # Conductor width Conductor width Conductor hole dia Insulated Coil Clearance to envelope Current Density Temperature rise Water velocity Water Pressure Drop Subcoil String flow rate Voltage Subcoil String (PS voltage) Current Subcoil String (PS current) Power Subcoil String (PS power) Hybrid SC2 (1.02) Goal DP Total NI Number of turns LUVATA Conductor # Conductor width Conductor width Conductor hole dia Insulated Coil Clearance to envelope Current Density Temperature rise Water velocity Water Pressure Drop Subcoil String flow rate Voltage Subcoil String (PS voltage) Current Subcoil String (PS current) Power Subcoil String (PS power) 100% 100 7752 100% 100 2850 4 2 10000 8449 W H d C mm mm mm mm A/mm C ft/sec psi gpm V A kW 13 13 W H d C mm mm mm mm A/mm C ft/sec psi gpm V A kW 13 13 8. 5 4. 2 6 15. 5 17.4 19.4 12.7 100. 0 48. 6 123. 3 1938. 0 239. 0 10.2 16.5 11.0 100. 0 10. 5 30. 8 1425. 0 43. 9 DT V DP F V I P DT V DP F V I P
Ver y good </ = 15 25 12 Desi gn Goal OK </ = 20 35 15 Too Hi gh > 30 45 20 Hi gh</ = 30 45 20 HYBRID DS Cur r ent densi t y Tem per at ur e r i se W at er vel oci t y Hybrid SC3 (1.02) Goal DP Total NI Number of turns LUVATA Conductor # Conductor width Conductor width Conductor hole dia Insulated Coil Clearance to envelope Current Density Temperature rise Water velocity Water Pressure Drop Subcoil String flow rate Voltage Subcoil String (PS voltage) Current Subcoil String (PS current) Power Subcoil String (PS power) Hybrid SC4 (1.02) Goal DP Total NI Number of turns LUVATA Conductor # Conductor width Conductor width Conductor hole dia Insulated Coil Clearance to envelope Current Density Temperature rise Water velocity Water Pressure Drop Subcoil String flow rate Voltage Subcoil String (PS voltage) Current Subcoil String (PS current) Power Subcoil String (PS power) 100% 100 6260 100% 100 12300 4 10 8185 6819 W H d C mm mm mm mm A/mm C ft/sec psi gpm V A kW 13 13 W H d C mm mm mm mm A/mm C ft/sec psi gpm V A kW 13 13 10 9 25. 6 5. 7 15.0 20.6 10.6 100. 0 22. 8 75. 9 1565. 0 118. 8 13.9 11.8 10.9 100. 1 57. 9 140. 5 1230. 0 172. 9 DT V DP F V I P DT V DP F V I P
Ver y good </ = 15 25 12 Desi gn Goal OK </ = 20 35 15 Too Hi gh > 30 45 20 Hi gh</ = 30 45 20 SEGMENTED DS Cur r ent densi t y Tem per at ur e r i se W at er vel oci t y Segmented 1 (1.03) Goal DP Total NI Number of turns LUVATA Conductor # Conductor width Conductor width Conductor hole dia Insulated Coil Clearance to envelope Current Density Temperature rise Water velocity Water Pressure Drop Subcoil String flow rate Voltage Subcoil String (PS voltage) Current Subcoil String (PS current) Power Subcoil String (PS power) Segmented 2(1.03) Goal DP Total NI Number of turns LUVATA Conductor # Conductor width Conductor width Conductor hole dia Insulated Coil Clearance to envelope Current Density Temperature rise Water velocity Water Pressure Drop Subcoil String flow rate Voltage Subcoil String (PS voltage) Current Subcoil String (PS current) Power Subcoil String (PS power) 100% 100 8914. 8 100% 100 12192. 3 4 6 7034 12. 7 12. 7 4. 5 4. 1 8426 W H d C mm mm mm mm A/mm C ft/sec psi gpm V A kW 14 14 W H d C mm mm mm mm A/mm C ft/sec psi gpm V A kW 6 14. 5 12.2 14.8 13.0 15.4 23.2 13.9 DT V DP F V I P DT V DP F V I P 98. 8 12. 4 22. 9 98. 9 7. 5 19. 7 2032. 1 46. 6 2228. 7 43. 8 Segmented 3 (1.03) Goal DP Total NI 100% 100 19391. 3 8 LUVATA Conductor # Conductor width Conductor width Conductor hole dia Insulated Coil Clearance to envelope Current Density Temperature rise Water velocity Water Pressure Drop Subcoil String flow rate Voltage Subcoil String (PS voltage) Current Subcoil String (PS current) Power Subcoil String (PS power) 8151 W H d C mm mm mm mm A/mm C ft/sec psi gpm V A kW 15 15 7 23. 6 13.1 20.0 12.2 DT V DP F V I P 98. 9 15. 8 33. 1 2423. 9 80. 3
Ver y good </ = 15 25 12 Desi gn Goal OK </ = 20 35 15 Too Hi gh > 30 45 20 Hi gh</ = 30 45 20 SEGMENTED DS Cur r ent densi t y Tem per at ur e r i se W at er vel oci t y 5 turns per pancake 4 turns per pancake Segmented 4 ANC V2 Goal DP Total NI Number of turns LUVATA Conductor # Conductor width Conductor width Conductor hole dia Insulated Coil Clearance to envelope Current Density Temperature rise Water velocity Water Pressure Drop Subcoil String flow rate Voltage Subcoil String (PS voltage) Current Subcoil String (PS current) Power Subcoil String (PS power) Segmented 4 ANC V3 Goal DP Total NI Number of turns LUVATA Conductor # Conductor width Conductor width Conductor hole dia Insulated Coil Clearance to envelope Current Density Temperature rise Water velocity Water Pressure Drop Subcoil String flow rate Voltage Subcoil String (PS voltage) Current Subcoil String (PS current) Power Subcoil String (PS power) 100% 100 33534 100% 100 33534 10 8 6895 22. 2 18. 3 6895 22. 2 18. 3 W H d C mm mm mm mm A/mm C ft/sec psi gpm V A kW W H d C mm mm mm mm A/mm C ft/sec psi gpm V A kW 11 11 9. 5 9. 5 10.8 19.8 11.56 13.5 21.9 13.07 100. 3 84. 0 111. 3 4191. 8 466. 5 DT V DP F V I P DT V DP F V I P 99. 9 74. 3 110. 9 3353. 4 371. 8
BACKUP Clearances to Particle Envelopes O:\Magnet_Design_Tools\Magnet Projects\MOLLER - Hall A\5. Preliminary Drawings - uncontrolled\Beamline Cad\ENVELOPE CLEARANCES Filename: COIL CLEARANCES 2_RRW_dk.xlsx Worksheet: Nov 2020
UPSTREAM TOROID DOWNSTREAM TOROID SC1 SC2 SC3 SC4
UPSTREAM Section A-A A-A B-B B-B C-C C-C Z 1150 1150 2000 2000 2850 2850 Average Clearance of US Torus inner Average Clearance of US Torus outer clearance @ inner turns (mm) clearance @outer turns (mm) clearance @ inner turns (mm) clearance @outer turns (mm) clearance @ inner turns (mm) clearance @outer turns (mm) Min clearance of US inner Min clearance of US outer Magnet Type US and Hybrid 3.66 N/A 5.58 38.63 6.94 41.09 5.4 39.9 3.7 38.6 US and Segmented 1.03 3.80 N/A 5.51 37.77 7.07 39.71 5.5 38.7 3.8 37.8 US and Seg V2DSg.1b_4 TURN SC4 US and Seg V2DSg.1a_5 TURN SC4
DOWNSTREAM SC1 Section D-D D-D E-E E-E Z 5100 5100 5800 5800 clearance @ inner turns (mm) clearance @outer turns (mm) clearance @ inner turns (mm) clearance @outer turns (mm) Average Clearance of SC1 inner Average Clearance of SC1 outer Min clearance of SC1 inner Min clearance of SC1 outer Magnet Type US and Hybrid 2.78 18.56 3.88 19.98 3.3 19.3 2.8 18.6 US and Segmented 1.03 2.79 19.78 3.88 21.5 3.3 20.6 2.8 19.8 US and Seg V2DSg.1b_4 TURN SC4 US and Seg V2DSg.1a_5 TURN SC4
DOWNSTREAM SC2 Section F-F F-F G-G G-G Z 6100 6100 6800 6800 clearance @ inner turns (mm) clearance @outer turns (mm) clearance @ inner turns (mm) clearance @outer turns (mm) Average Clearance of SC2 inner Average Clearance of SC2 inner Min clearance of SC2 inner Min clearance of SC2 outer Magnet Type US and Hybrid 4.29 28.73 4.95 23.52 4.6 26.1 4.3 23.5 US and Segmented 1.03 3.00 29.02 3.66 22.3 3.3 25.7 3.0 22.3 US and Seg V2DSg.1b_4 TURN SC4 US and Seg V2DSg.1a_5 TURN SC4
DOWNSTREAM SC3 Section H-H H-H J-J J-J Z 7100 7100 7700 7700 clearance @ inner turns (mm) clearance @outer turns (mm) clearance @ inner turns (mm) clearance @outer turns (mm) Average Clearance of SC3 inner Average Clearance of SC3 outer Min clearance of SC3 inner Min clearance of SC3 outer Magnet Type US and Hybrid 5.34 19.66 6.3 30.33 5.8 25.0 5.3 19.7 US and Segmented 1.03 3.05 20.33 4.01 18.05 3.5 19.2 3.1 18.1 US and Seg V2DSg.1b_4 TURN SC4 US and Seg V2DSg.1a_5 TURN SC4
DOWNSTREAM SC4 Section K-K K-K L-L L-L M-M M-M N-N N-N P-P P-P R-R R-R T-T T-T including cooling Tubes including cooling Tubes including cooling Tubes including cooling Tubes Z 8200 8200 8400 8400 9300 9300 9900 9900 10600 10600 11400 11400 11600 11600 Just coils Just coils clearance @ inner turns (mm) clearance @outer turns (mm) clearance @ inner turns (mm) clearance @outer turns (mm) clearance @ inner turns (mm) clearance @outer turns (mm) clearance @ inner turns (mm) clearance @outer turns (mm) clearance @ inner turns (mm) clearance @outer turns (mm) clearance @ inner turns (mm) clearance @outer turns (mm) clearance @ inner turns (mm) clearance @outer turns (mm) Average clearance of SC4 inner Average clearance of SC4 outer Min clearance of SC4 inner Min clearance of SC4 outer Min clearance of SC4 inner Min clearance of SC4 outer Magnet Type US and Hybrid 6.86 7.63 7.36 11.9 10.13 2.72 11.67 12.69 13.74 15.24 17.31 12.55 17.93 12.79 12.1 10.8 6.9 2.7 6.9 2.7 US and Segmented 1.03 6.26 4.62 7.23 10.26 10.01 1.40 11.55 12.57 13.62 15.12 17.18 6.34 17.81 6.53 12.0 8.1 6.3 1.4 6.3 1.4 US and Seg V2DSg.1b_4 TURN SC4 16.99 17.06 17.49 17.56 20.27 11.66 21.80 23.10 23.87 17.94 27.44 8.44 26.96 6.01 22.1 14.5 17.0 6.0 US and Seg V2DSg.1a_5 TURN SC4 16.99 18.61 17.49 17.67 20.27 11.66 21.8 22.19 23.87 17.44 27.44 8.51 26.96 6.27 22.1 14.6 17.0 6.3
