Series manufacture of the LHC main. dipole magnets. Notes about the CERN. approach to industrial. production. C.Wyss & L.

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1 Series manufacture of the LHC main dipole magnets Notes about the CERN approach to industrial production C.Wyss & L.Rossi / CERN SCRF05-12 July 2005 L.Rossi & C.Wyss - CERN 1

2 units, 8.3 T nominal field, 9 T ultimate field, 2 x 56 mm coil apertures, 15 m long, 28 t heavy Total value before cryostating: about 1BCHF (800 M$) Design and model work (1-m length) at CERN Full-length prototype collared coils made in industry (3 vendors) All prototype cold mass assembled at CERN Pre-series contracts for 3 x 30 cold masses Assembly of the first 2-4 pre-series cold masses / vendor at CERN, to train industry personnel Series contracts for 3 x 416 cold masses, after full testing of 2 preseries units/vendor and manufacture of 6-8 pre-series units/vendor SCRF05-12 July 2005 L.Rossi & C.Wyss - CERN 2

3 Highest magnet uniformity (10-4 ) necessary for best machine performance and simplest installation sequence in the tunnel For the pre-series, all main components were directly procured by CERN, providing thus the contractors qualification by CERN For series production, nearly all main components were directly procured by CERN (45 contracts, 4 inter- laboratory agreements - India, Russia, USA) Double source for critical items: SC cables, fine-blanked parts (collars and laminations) and corrector magnets All other CERN provided materials and components are from a single source Number of contracts minimized to achieve economies of scale and minimize the amount of CERN resources for close follow-up SCRF05-12 July 2005 L.Rossi & C.Wyss - CERN 3

4 Heavy tooling designed and procured by CERN, except for coil winding machines and coil curing presses Essential quality control equipment (coil e-module, geometrical, electrical, field quality) designed and supplied by CERN Maximum sharing of know-how among the CERN staff in charge of contract follow-up Implementation of Statistical Process Control (SPC) for the properties of materials, components, sub-assemblies and of the warm and cold tested magnets. Resident inspectors under CERN contract at the vendors premises SCRF05-12 July 2005 L.Rossi & C.Wyss - CERN 4

5 Responsibility for design and performance with CERN Responsibility for faultless assembly with the vendors Responsibility for operation and maintenance of the tooling with the owners of the tooling design Quality checks after completion of each main assembly step to intercept errors at the earliest moment and minimize the loss of added value Bonus (1% ) for magnets needing no more than three quenches to reach 9 T (reduced test time and hence cost for CERN) SCRF05-12 July 2005 L.Rossi & C.Wyss - CERN 5

6 Status on June 30, 2005 Dipole cold masses C.M.Contractual Sep-06 Jul-06 May-06 Mar-06 Jan-06 Nov-05 Sep-05 Jul-05 May-05 Mar-05 Jan-05 Nov-04 Sep-04 Jul-04 May-04 Mar-04 Jan-04 Nov-03 Sep-03 Jul-03 May-03 Mar-03 Jan-03 Nov-02 Sep-02 Jul-02 May-02 Mar-02 Jan-02 Nov-01 Sep-01 Jul-01 May-01 Mar-01 Jan SCRF05-12 July 2005 L.Rossi & C.Wyss - CERN Collared coil accepted Just in time C.M. Delivered Years

7 Status on June 30, 2005: (71 %) collared coils accepted (61 %) cold masses delivered (51%) cryomagnets cold tested Rejected cold masses: for unsatisfactory quench performance - 10 for electrical failure (mostly quench heaters) - 2 for mechanical non-conformities SCRF05-12 July 2005 L.Rossi & C.Wyss - CERN 7

8 11 cold masses repaired without magnet disassembly 15 cold masses were disassembled (9 for quench performance, 6 for electrical failure) Out of the 26 rejected cold masses, 25 were repaired and only one was scrapped About 60% of the defaults could be clearly ascribed to assembly errors or to the non-respect of agreed procedures For the remaining 40 %, the responsibility was shared between CERN and the vendor The ramping up of series manufacture is the period were most errors occurred, because of the training of additional staff SCRF05-12 July 2005 L.Rossi & C.Wyss - CERN 8