Status of the tooling
Part 1:From Winding to impregnation
Raúl Morón BallesterTE-MSC-LMF
From winding to impregnation – Raúl Morón Ballester 2
FNAL
CERN MDT
CERN LMF
Babcock NoellAlstom
11T Prototype (5.5m) Manufacturing system
11T Model Manufacturing system
11T Model Manufacturing system
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Outlook• Winding• Curing• Reaction/Splicing• Impregnation• Tooling delivery VS. Planning• Conclusions
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WindingWINDING MACHINE:• Modifications:
• Update of the control program• Shortening of the bench• Elevation of the gantry• New tension-meter• Outer spool holder to support two-layer-winding without internal splice
• Status: Tension control needs improvement – Not critical
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WindingWinding mandrel and accessories
Status: Ready
Handling equipment for spool manipulation
Status: Ready
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CuringCURING PRESS:• Modifications:
• Hydraulic system has been modified to allow more pressing configurations• Update of the control system• Resistance heaters instead of warm oil• Extension of the bench to hold the outer spool
• Status: Ready
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Interlayer tool
Status: Ready
CuringCuring Mould
Status: Half shelves shall be modified – Not critical
Curing Jacket
Status: Ready
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Lifting girder for curing mould
Status: Ready
Curing - Handling
Coil storing tool
Status: Ready
Coil Handling tool
Status: Delivered. Waiting for load tests (W51)
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ReactionReaction furnace
Improvements:- More robust ventilation system
- Two oxygen sensors (Reaction Fixture + Retort)
Status: Ready
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ReactionReaction mould
Status: Some blocks to be re-done. Delivery end of December
- Argon flow is done from mid-plane to poles instead of axially.
- The blocks rest directly on the base plate instead of the seal plates
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Reaction - SplicingLifting tool for mould
Status: Ready
Splicing tool
Status: Manufacturing launched (in-house)
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R-S-I HandlingRotating table for Winding – Splicing - Impregnation
Status: Offers received, contract to be placed on W51. Delivery: Mid-March
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ImpregnationVACUUM PRESSURE IMPREGNATION SYSTEM• Characteristics:
• Pressure difference injection or dosing pump injection• Mixing and outflow reservoirs outside the vacuum chamber• Possibility to apply pressure up to 5 bar in each of the reservoirs independently• Tilting of the chamber up to 18 degrees• Auto-cleaning
Status: Technical documents approved. Components ready by first week of January. First injection tests end of January. Machine commissioned: end of March.
Credits: Elytt Energy
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ImpregnationImpregnation mould
Status: DO launched Expected end of March
Resin injection can be done from base to top or axially (Axial method has been the usual up to now, but radial method is being tested due to its scalability)
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Tooling delivery VS. Planning
Missing tool Expected Needed
Winding tension control improvement End of February Mid March
Half-shelves for curing mould Mid-February Mid-March
Coil Handling tool Delivered - To be tested Mid-April
Reaction Mould - Extra blocks End of December First half of January
Splicing tool End of January Mid-February
Rotating table Mid-March End of March
Impregnation fixture End of March End of April
Vacuum Pressure Impregnation System End of March End of April
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Conclusions• The process has been proven successful up
to curing.
• The reaction and impregnation changes always allow a fall-back solution. Tests are in progress to validate the concepts.
• The delivery of the missing tooling/machines does not interfere with the planning.
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Acknowledgments• F. Savary, H. Prin, S. Luzieux, S. Izquierdo Bermudez,
F. Lackner, R. Principe, L. Grand-Clement, E. Grospellier, C.H. Löffler, J.C. Perez, F.O. Pincot, R. Gauthier,D. Smekens, J. Mazet, M. Karppinen, T. Sahner, J. Parrilla Leal, A. Temporal, L. Favre, C. Mucher (CERN)
• A.R. Nobrega (FNAL)• P. Revilak, S. G. Will (Babcock Noell)• V. Letellier, T. Genestier (Alstom)