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Abstract
Manufacturing and Quality Assurance
Frank DePaola, NSLS-II Project
Building Quality into the Magnets necessitates that the quality requirements for the performance specifications
are incorporated into the production process and methods used to produce the magnets. This is accomplished
through manufacturing travelers, documented procedures, early QA involvement that takes a proactive approach
for preventing defects, and the use of established best practices for manufacturing the coils and yokes.
*Work performed under auspices of the United States Department of Energy, under contract DE-AC0298CH10886
OUTLINE
Magnet Production
Manufacturing Travelers
The single most important item is the manufacturing traveler
Ideally all magnets from the same family are manufactured from a
single batch of steel (same heat)
Gluing is generally used for magnets that are < 0.5 meter in length
Trying to glue dipole magnets that have a long length to yoke cross
section ratio is very difficult to accomplish and stacking curved
dipole magnets adds yet another level of complexity
Magnet Production Workshop April 11-12, 2012
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BROOKHAVEN SCIENCE ASSOCIATES
Important to handle the laminations wearing clean lint free gloves and
cleaning the laminations prior to stacking using a recommended or
proven cleaning method
Magnet Production Workshop April 11-12, 2012
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BROOKHAVEN SCIENCE ASSOCIATES
Vacuum impregnation of the coils and the use of a potting mold was
specified in order to accurately produce the coils final shape and close
mechanical tolerance requirements for
Coat the inside surfaces of the mold cavity with a mold releasing agent
to facilitate the removal of the cured coil
G10 strips are used to center the wound coil within the mold allowing
the epoxy to flow uniformly around the entire coil assembly
In order to completely evacuate air from the mold cavity The vacuum
pump draws the mixed epoxy into the cavity from the bottom of the
mold completely fills the cavity and exists through the top of the
mold
Alumina filled epoxy resin prolongs the life of the coils by providing
added radiation resistance Getting the mixture to flow uniformly
through the mold cavity proved to be a challenging task for most until
the exact recipe (alumina particle size, mixing time and temperature)
was established
Magnet Production Workshop April 11-12, 2012
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BROOKHAVEN SCIENCE ASSOCIATES
Magnet Assembly
Secondary Processing
Small variations during fabrication and assembly have
an adverse effect on magnet performance and
repeatability.
Reducing these variations to an acceptable level
requires secondary processing of the magnet after
bonding and assembly.
Magnet Assembly
Secondary Processing
To achieve the high precision quality requirements of the magnetic field
and to ensure repeatable magnetic performance after disassembly and
reassembly of the magnet
Machine the mating registration surfaces of each yoke half and each
mid-plane spacer
Best magnetic field quality results are achieved when the pole profile is
machined in the assembled magnet
Magnet Production Workshop April 11-12, 2012
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Acknowledgements