Task7: NUSTAR2 - Design and Prototype Construction of a Radiation-Resistant Magnet C. Mühle GSI Task leader: G. Moritz /GSI.

Task7: NUSTAR2 - Design and Prototype Task7: NUSTAR2 - Design and Prototype Construction of a Radiation-Resistant MagnetConstruction of a Radiation-Resistant Magnet

C. Mühle

GSI

Task leader: G. Moritz /GSI

High-radiation area

Design parameters and layout of the Super-FRSDesign parameters and layout of the Super-FRS

Magnets in the high radiation area

Quantity Field/gradient

Length

Usable apert.

Gap height/Pole radius

Dipole 1

11°

3 0.15-1.6T

2.39m

380x140mm

170mm

Quadrupole 1

Ap.rad.10cm

2 1.5-15T/m

1m

Ø90mm

100mm

Quadrupole 2

Ap.rad.20cm

1 0.8-7.6T/m

1m

380x200mm

200mm

Sextupole 1 2 1.5-14T/m2

0.6m

380x200mm

200mm

Recap of first yearRecap of first year

Original idea:

Use of superconducting radiation resistant dipoles

Investigation of radiation loads:

Heat load on the cryogenic system for a 5 ton magnet: ≈ 2.3 kW (expected FAIR cryogenic power: 20 kW) => economic operation not possible

Decision

Normal conducting magnets with mineral insulated cable (MIC)

Surveying and alignment system for high-radiation areas

Not directly influenced by this decision

=> Main work in 2006 was dedicated to the conceptual design of a dipole with MIC

Conceptual design of a dipole with MIC: Conceptual design of a dipole with MIC: CoolingCooling

Cooling options:direct: hollow conductorindirect: solid conductor + radiator

Direct cooling:Advantage: good heat transferDisadvantage: radiolysis

Indirect cooling:Advantages:

• pressure drop and cooling power can be designed independently from coil

• no radiolysis• water and power

connectors separatedDisadvantage: limited heat transfer

Decision: indirect cooling

Conceptual design of a dipole with MIC: CoilConceptual design of a dipole with MIC: Coil

Conductor:Cable Size 19mm x 19mm Sheath Thickness 1 mmInsulation Thickness 1 - 1.5 mmCond. Area 190 mm2 Unit Length 100m

Radiator:Copper plate 12 mm thickStainless steel tube 10x1mm

Coil system:2 x 192 turns, 12 columns, 2 x 16 layers 2 x 8 double pancakes≈ 100 m conductor per single pancaketotal conductor length ≈ 3.2 km

Conceptual design of a dipole with MIC: YokeConceptual design of a dipole with MIC: Yoke

Requirements:

α=11°, r=12.5m, Bmax=0.15-1.6T L=2.39mUseful aperture 380x140mm (ΔB/B≤±2x10-4)Gap height 170mm

Yoke designH-typeCurvedLaminated

• thickness 2 bis 4 cm• cut by laser• final milling of pole profile

Cross section 2740mm x 2020 mmYoke weight 85 tPole shims but no active correctionLongitudinal split into 3 parts

Conceptual design of a dipole with MIC: Dipole Conceptual design of a dipole with MIC: Dipole operationoperation

I=610A

P=122kW

Cooling

ΔT=21.9K

79.2 l/min @ 1bar

Conductor temperature:

Return water temperature +40K

Construction of a prototype dipole with MICConstruction of a prototype dipole with MIC

To be done in the remaining project time:

Manufacturing design

Production of tooling and first (test) double pancake

Production of full coil

Production of yoke

Assembly of final magnet

Time scale

≈ 1 year => close to the limit, but still feasible

Cost estimation of prototype magnet incl. tooling: 1.5 M€

Budget

This task: 568 k€ (50%EU,50%GSI)

Budget gap: ≈ 950 k€• Redirect money from other tasks• Finance remaining gap by GSI

SurveyingSurveying and alignment system for high-radiation areasand alignment system for high-radiation areas

Measurement concept and simulation of alignment approach nearly finished Photogrammetric solution on Super-FRS target area working platform with four

cameras on two movable vehicles Sequential photogrammetric survey of inaccessible areas during shutdown

Surveying and alignment system for high-radiation Surveying and alignment system for high-radiation areasareas

Problems to solve: mounting and fiducialization of excentric magnet

points Penetration of shielding between magnets and

working platform Remote-controlled adjustment of magnet positions

(radiation! weight!)