linac4 drift tube linac liu day 2014
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Linac4 Drift Tube Linac LIU Day 2014. Suitbert Ramberger, CERN, BE- RF- LRF. Linac4 DTL – RF Design. Introduction Design Parameters & Constraints Production Design Mechanical Concept Manufacturing and Assembly Manufacturing in Industry and at CERN Quality Issues Current Status - PowerPoint PPT PresentationTRANSCRIPT
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Linac4 Drift Tube LinacLIU Day 2014
Suitbert Ramberger, CERN, BE-RF-LRF
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Linac4 DTL – RF Design
● Introduction
– Design Parameters & Constraints
– Production Design
– Mechanical Concept
● Manufacturing and Assembly
– Manufacturing in Industry and at CERN
– Quality Issues
– Current Status
● Results of Tank1
– Quadrupole Positioning
– Field flatness
● Conclusions
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Linac4 Drift Tube Linac
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Linac4 DTL Design
DTL design parameters:● DTL from 3 – 50 MeV with 3 cavities and 1 LEP and 2 new klystrons● Klystron output power at cavity port 1 MW (Tank1) and 2 MW (Tank2&3)● Accelerating field at ~3.2 MV/m● Peak electric field of 1.6 Kilpatrick lowered to 1.2 Kilp. over the first cells● PMQs in vacuum● Self supporting steel cylinders of 50 mm thickness● Maximum segment length of 2 m
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Linac4 DTL Design
Parameter \Cavity
1 2 3
Cells per cavity 39 42 30
Accelerating field 3.1 MV/m 3.3 MV/m 3.3 MV/m
Maximum surface field 1.5 Kilp. 1.4 Kilp. 1.45 Kilp.
Synchronous phase -35 to -24 deg -24 deg -24 deg
RF peak power per cavity 1.00 MW 2.03 MW 1.98 MW
Quadrupole length 45 mm 80 mm 80 mm
Flat Size 11 mm 7 mm 5 mm
Number of sections 2 4 4
Length per cavity 3.8958 m 7.3406 m 7.2508 m
Beam output power 11.88 MeV 31.45 MeV 50.14 MeV
Production design:● RF design compatible with mechanical realization
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Linac4 DTL– Mechanical Design
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Linac4 DTL Mechanical Design
Linac4 Drift Tube Linac Mechanical Design:Make it as straightforward as possible:● Mechanical Design without position adjustment of Drift Tubes● Single Helicoflex gaskets for vacuum and RF sealing● Coaxial water cooling in Drift Tubes● No wires in Drift Tubes: PMQs, no instrumentation, thermal probes at top● Rigid steel support structure, w/o welds (almost), soft Aluminium girders
Consequence:● Precision Machining required, and tight Quality Control
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CERN Drift Tube Positioning
“Adjust and Assemble”
Horizontal andvertical positioning
Vacuum seal
Cooling water in
Cooling water out
Belleville washers
Pre-stress cylinder
Leak test seal
Thermo-probe andLeak test channel
Base plate
Bushing
Screw
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Linac4 DTL Manufacturing
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Linac4 DTL Manufacturing
Linac4 Drift Tube Linac Manufacturing:● Girder manufacturing at CADINOX, Veenstra Glazenborg & CERN● Retendering to Mancisidor and GoiAlde, Spain → Completed June 2013 ● Drift tube component machining, DMP, Spain → Completed January 2013● Drift tube assembly, CERN → Completed November 2013● Tank manufacturing at CADINOX, Spain → Completed February 2014● Tank plating, CERN → 5 Segments Completed, 1 Ongoing, 4 Waiting● Tank assembly, CERN → Tank1 Completed, Tank3 Ongoing
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Tank Manufacturing
Tank manufacturing:● Order started November 2010● Manufacturing of 1 pre-series segment T1S1 completed October 2011
– Pre-series segment fully in specification● Machining error on deep drilled cooling channels found March 2012
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Cooling channel repair
Crash program:● Definition of analysis procedure by ultrasound● Analysis of all segments: 9 segments out of tolerances, 2 to be repaired● Definition of repair with inserts● Successful test on sample pieces at manufacturer● Ordering of dedicated machining tool● Machining of defined channel opening● Failed repair on tank segments at manufacturer● Remachining of defined channel opening● Successful repair at CERN – T3S3 sent back, T1S2 at CERN (May 2013)
Other issues:
● Other leaks (water to air) plugged● Re-machining of segments out of tolerances● Non-connected cooling channel
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Linac4 DTL Tank Status
Tank status:● T1S1 & T1S2 assembled and joined as Tank1 – in completion● T3S1, T3S2 & T3S4 assembled● T3S3 under copper plating● T2S1-S4 at CERN
Current tasks:● Verifications and completion of Tank1● Copper plating of remaining segments in competition with LS1● Assembly of segments of Tank3
● Manufacturing of wave-guide couplers & movable tuners
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Linac4 DTL Tank1 Results
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Linac4 DTL Tank1 Results
Quadrupole positioning: Horizontal / Longitudinal / Vertical
J.-F. Fuchs
T1S1_
DT101
T1S1_
DT103
T1S1_
DT105
T1S1_
DT107
T1S1_
DT109
T1S1_
DT111
T1S1_
DT113
T1S1_
DT115
T1S1_
DT117
T1S1_
DT119
T1S1_
DT121
T1S2_
DT123
T1S2_
DT125
T1S2_
DT127
T1S2_
DT129
T1S2_
DT131
T1S2_
DT133
T1S2_
DT135
T1S2_
DT137
-0.100
-0.080
-0.060
-0.040
-0.020
0.000
0.020
0.040
0.060
0.080
0.100X avg horiz. mm
Y avg long. mm
Z avg vert mm
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Linac4 DTL Tank1 Results
Tuning: E0 variation within +/- 1.35%
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 390.985
0.99
0.995
1
1.005
1.01
1.015
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Linac4 Drift Tube Linac – Conclusions
Conclusions:
● The Linac4 Drift Tube Linac is a prototype
● Manufacturing requires tight quality control
● Considerable quality issues have been overcome
● Almost all major components have been completed
● Last manufacturing stages are in competition with LS1
● The Drift Tube Linac is a puzzle of a thousand pieces
● Final assembly is on its way