SERIES PRODUCTION OF SUPERCONDUCTING MAGNETS FOR PARTICLE ACCELERATORS: THE INDUSTRIAL EXPERIENCE

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Veronica Mendoza Ortíz
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1 SERIES PRODUCTION OF SUPERCONDUCTING MAGNETS FOR PARTICLE ACCELERATORS: THE INDUSTRIAL EXPERIENCE Rafael Iturbe, Madrid 27/05/

2 ANTEC LOCATIONS 1992 Establishment 2007 China 2013 Brazil ANTEC S.A. Portugalete Vizcaya (SPAIN) (47 Employees) ANTEC BRAKING SYSTEMS Tianjin (CHINA) (25 Employees) ANTEC (BRAZIL) ( Employees) (2013) TURNOVER (2012) 18 M + 2

BRAKING SYSTEMS Tianjin (CHINA) (25 Employees) ANTEC

3 PRODUCT LINES Wind Energy Brakes (85%) Industrial Brakes (10%) Precision Magnetic Systems (5%) 3

4 PRECISION MAGNETIC SYSTEMS Particle accelerator magnets: Warm magnets Warm quadrupoles (ESRF) Warm combined dipole (ALBA) Prototype MEBT warm combined Quadrupole (IFMIF) Prototype CELLS booster quadrupoles (ALBA synchrotron) REX ISOLDE dipole (CERN) LINAC dipole (CERN) QTL quadrupole (ESS Bilbao) Prototype 4

Quadrupole (IFMIF) Prototype CELLS booster quadrupoles (ALBA synchrotron) REX

5 PRECISION MAGNETIC SYSTEMS Particle accelerator magnets: Superconducting magnets (SERIES) 120 Deliveries XFEL U n its jun12 sep12 dic12 mar13 jun13 sep13 dic13 mar14 jun14 Dates LHC MCS Corrector sextupole (CERN) LHC MO Corrector octupole (CERN) XFEL Combined magnet 2 dipoles + SF quadrupole 5

jun13 sep13 dic13 mar14 jun14 Dates LHC MCS Corrector sextupole (CERN) LHC MO

6 SUPERCONDUCTIVITY R&D AT ANTEC AMIT PROJECT (FUNDED BY CDTI) BUDGET 18,7 M 10 Industrial Partners 13 Research Centres 3 External partners RADIOISOTOPE RADIOTRACER IMAGE IMAGE PRODUCTION PRODUCTION ACQUISITION PROCESSING 6

Centres 3 External partners RADIOISOTOPE RADIOTRACER IMAGE

7 SUPERCONDUCTIVITY R&D AT ANTEC MgB 2 COILS Design of coils, tools and winding of new SC material (SUPERTUR Project) 7

8 OVERVIEW OF SERIES PRODUCTION CONTRACTS BIDDER FINANCIAL ASPECTS QUALITY ASSURANCE MANUFACTURE 8

9 CONTRACTS (SERIES) BIDING PROCEDURE PAYMENT CONDITIONS MARKET SURVEY PREQUALIFICATION (Bidders) 510% At SIGNATURE (Bank guarantee until END of guarantee period) CALL FOR TENDERS QUOTATION 510% At manufacturing drawings & schedule (Bank guarantee until end of production) BID DEFENSE QUALIFICATION (Technical + Budget) 510% At PreSeries acceptance 7085% At magnet acceptance CONTRACT 9

manufacturing drawings & schedule (Bank guarantee until end of production) BID DEFENSE

10 CHALLENGES IN SERIES PRODUCTION Costs reduction Production means Manufacturing Procedures Tools Man power Materials Production reliability Quality Plan Work Flows Training of personnel Manufacturing Procedures Tools (Reproducibility) Test stations Feed back from client 10

reliability Quality Plan Work Flows Training of personnel Manufacturing

11 QUALITY PLAN GENERAL PROCESOS DE CONTROL CONTROL DE LA ESPECIFICACIÓN CP MCS## Nº OPERACIÓN DESCRIPCION FR. AUD. TR AV. DATOS TRAV. DOC. INT. DATOS DOCUM.S INTERNOS 1 MCS01,02 C.Dim.End Saddles y Central Post R,C Id, Drwg, Certif., B. Size, Sample y C.Dim 2 MCS04 Confección Bobinas si C.P. Id, Drwg, Wire Id, CE y NCE Id C,P W. Dim, resin, endur., 3 MCS 03,05,06,07 Preparación Mandrino, Curado, Ensayos y Limpieza C,P ciclo curado, L, R y cortos 4 MCS08 Control Dimensional Bobinas C C. Dim. 5 MCS09 Montaje y Curado Coil Assembly si Id, Drw, Id coils, Id Sheet, CX Id, STube Id P Resina, Endur., C. Curado, C. Dim., Cert. Tube & Sheet 6 MCS 10,11,13 Control Dim. Laminaciones, Zunchos y Bandages Lam. :Id, Drw., C.Mat, Nº y Tam. lote, Mues., C.D., Trat. R, C Zunchos: Id, Drwg, Mat. Cert., C. Dim., Tratam. Bandaje C. Dim. 7 MCS12 Mecanizado Bandage P Fecha 8 MCS14 Extracción Mandrino P 9 MCS 15,20,21 Soldadura Bobinas, Liras y Busbar supra P Parám. Sold. 10 MCS16 Ensayos Electricos Coil Assembly si R, L P Ens. Cortos 11 MCS17 Aplicación Stycast y Limpieza P Fecha 12 MCS18 Fabricación Módulo si Id, C.A. Id, Lam Id, Zuncho Id P Fecha 13 MCS19 Control Dimensional Módulo C 11

, 3 MCS 03,05,06,07 Preparación Mandrino, Curado, Ensayos y Limpieza C,P ciclo curado, L, R y cortos 4 MCS08 Control Dime

12 QUALITY PLAN MANUFACTURING WORK FLOWS 12

13 QUALITY PLAN MANUFACTURING PROCEDURES 13

14 QUALITY PLAN TRAVELLERS TRAVELLERS (Database): Traceability Complete Easy to fill in & consult 14

15 RECEPTION CONTROL Dimensional controls: Manual 3D Machine 15

16 COIL WINDING DIPOLE WINDING MACHINE TENSION CONTROL COS θ COILS DOUBLE PANCAKE WINDING MACHINE 16

17 COIL WINDING QUADRUPOLE 17

18 COIL ASSEMBLY Ultrasonic welding Machine LHC Magnets Tin soldering XFEL Magnets 18

19 PRODUCTION CONTROL Tools control Process controls (intermediate tests and controls) Dimensional Other: Electric 19

20 MAGNET ASSEMBLY 20

21 MAGNET ASSEMBLY 21

22 FINAL TESTS MAGNETIC MEASUREMENTS 22

23 FINAL TESTS TRAINING Quench current (A) TRAINING (COLD TESTS) MCS MAGNETS (8 at a time) 360 MO MODULES (4 at a time) Rate: Test of 4 Cryostats filling per week 23

24 THANK YOU FOR YOUR ATTENTION 24

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