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DOE OSTI2021

Study of Conduction-Cooled Superconducting Quadrupole Magnets Combined with Dipole Correctors for the ILC Main Linac

A superconducting rf (SRF) cryomodule for International Linear Collider(ILC) Main Linac equips focus/steering magnets. The magnets are "superferric" magnets with four superconducting (SC) race track coils conductively cooled from the cryomodule LHe supply pipe. The quadrupole field gradient and dipole field are 40 T/m and 0.1 T, respectively. The magnet length and iron-pole radius are 1 m and 0.045 m, respectively. It is known that dark current is generated at SRF cavities and accelerated through the following linac string. The dark current reaches and heats the SC magnets. It is estimated that the power deposition in the magnet may reach more than a few watts and temperature of the SC coils may locally reach to critical temperature of NbTi. It is important to make the magnet not reach quench with sufficient conduction cooling. We aim to realize the SC magnet which can stably operate under such condition. We plan to develop test coils made of three types of SC materials, NbTi, Nb₃Sn, and MgB₂ and study thermal characteristics and stability . We will develop a short model magnet, based on the test coil results. Here, we will present the magnet design study and the R&D plan.

43 PARTICLE ACCELERATORS↗

DOE OSTI2021

Regal Beloit Final Technical Report

The original project proposal submitted from NovaTorque Inc (NovaTorque) in 2016 was to improve the existing motor with 95% efficiency by reducing the losses by 21% to achieve 96%. A few months after the proposal was submitted, NovaTorque lost funding and went out of business. The assets of NovaTorque were then acquired by Regal Beloit Corporation (“Regal Beloit” or “Regal”). When the NovaTorque proposal was selected, the project was transferred to Regal Beloit. Once we had production samples from the new Regal production line, they were tested at the Regal Beloit test lab in Wausau, WI. The original NovaTorque motor had an efficiency of 95%, but when the technology was transferred to Regal Beloit, there were multiple manufacturing improvements made, even though the basic electromagnetic design did not change. The test results in Wausau showed that the motors made at the Regal Beloit plant had an efficiency of 96%. Since the goal of the project was to reduce the losses by 21%, a new efficiency target of 96.8% became the project objective. In the first budget period, motors were tested to get the baseline performance. We then used FEA modeling with ANSYS Maxwell to model the existing motor to get correlation between the FEA simulations and the actual test results. Once the model was validated, we evaluated some changes that could be made to the stator to reduce the losses and improve efficiency without changing the rotor or stator housing, keeping the modifications easy to implement. The changes were primarily in the area of making the stator axially shorter and adding Soft Magnetic Composite (SMC) tooth tips. In the second budget period, we proceeded to design and build the new stator that was identified above and identified additional improvements in the process that included a stator machining modification and the use of rectangular wire. When we actually built the motor, the choice of rectangular wire turned out to be a problem. The wire was made by squishing round wire to get the rectangular shape, which caused work hardening, making the wire too stiff to make the desired coils. We shifted to annealed square wire which was better, but we still could not maintain the proper coil envelope. The result was that we had reduced cross section area for stator laminations. We also had to have a radial offset resulting in a radial misalignment between the stator and rotor because of the oversized coils. After the motor was completed, it was shipped to Texas A&M University for testing. With the loss of flux from these issues, the measured motor efficiency was only 96.3%. The primary focus of this motor was to make sure our FEA simulation model predicted the measured losses and overall efficiency, this we moved on to the FEA simulation. The FEA simulations of the motor “as built” with misalignments had good correlation with the test results, so the next step was to use that model to optimize the design of the motor for a final build. This time we considered changes to the stator and rotor and also minor changes to the housing diameter. In the third budget period, we did the detailed design and construction of the final prototypes. The final prototypes had a slight increase in the stator diameter to fit in a standard Regal Beloit housing. We shortened the stator and use more layers of wire in the coils. We also increased the cone angle of the rotor and stator from the original 110 degrees to 130 degrees to get some additional efficiency and optimized the stator cross section. The predicted efficiency from the FEA simulations was 96.9%. When completed, the motors were tested. We were a little short of reaching our target efficiency goal of 96.8%. We were only able to get to 96.7% efficiency. While it may be possible with additional iterations in designs and future builds to gain that additional 0.1%, we believe that we are close to the best we can achieve from a practical viewpoint, and additional iterations would be more work than the potential gains would be worth. No other motor in this class can even reach the 96% that we started with.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Preliminary Sensitivity Analysis for Sensors Impacts on Building Control Performance

This report describes the preliminary sensitivity analysis for sensor impacts on building control performance through the US Department of Energy’s Oak Ridge National Laboratory’s Flexible Research Platform (FRP-2) building. The rooftop unit system provides cooling and heating to the building. The main heating coil is a gas heating coil. Each zone is served by a variable air volume box with an electricity reheat coil. The rooftop unit and variable air volume box controls adopted the practical control sequences from ASHRAE Guideline 36-2018: High-Performance Sequences of Operation. For sensors, the incipient (time-changing) sensor errors, including bias sensor error and precision sensor error, are the inputs of interest. The outputs are energy consumption and thermal comfort (e.g., the predicted percentage of dissatisfied occupants). The large-scale simulation (3,600 cases) was conducted on a cloud platform by integrating sensor errors and ASHRAE Guideline 36 control sequences into an emulator based on the EnergyPlus simulation program with Python energy management system feature. The surrogate models were developed based on cloud simulation results. The uncertainty analysis showed that the sensor errors substantially affect building energy consumption and thermal comfort. The sensitivity analysis shows a ranking of sensor error impacts for each interested output item (e.g., cooling energy, reheat coil heating energy, predicted percentage of dissatisfied occupants). In FY 2022, sensor locations, types, and costs will be evaluated. The field test in Oak Ridge National Laboratory’s Flexible Research Platform building regarding sensor impacts will also be performed. Finally, a comparative analysis will be conducted based on the field test results and emulator results.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Postirradiation Examination of WIRE-21 Experiment Irradiated in the High Flux Isotope Reactor

Westinghouse Electric Company is developing wireless sensors to monitor the centerline temperature and internal pressure of commercial light-water reactor fuel rods during irradiation. Oak Ridge National Laboratory and Westinghouse Electric Company developed the Wireless Instrumented RB Experiment 2021 (WIRE-21) to test wireless temperature and pressure sensor technologies in a removable beryllium position in the High Flux Isotope Reactor. The experiment was irradiated for a total of 75 days, at temperatures ranging from approximately 150°C to 400°C, resulting in a peak fast (energy > 0.1 MeV) neutron fluence of about 3 × 10 21 n/cm 2 . The temperature was intentionally cycled multiple times to compare the response of the wireless temperature sensor to collocated thermocouples. Similarly, the pressure sensor was actuated in multiple steps to compare the response of the wireless measurement to excore pressure transducers (Petrie et al., 2023). After irradiation, the experiment was disassembled in the Irradiated Fuels Examination Laboratory (IFEL) hot cell at Oak Ridge National Laboratory with the intent to recover sensor and dosimetry components, document the as-irradiated condition of the hardware, and investigate possible causes of the sensor behavior observed during irradiation. The postirradiation examination successfully recovered and preserved key WIRE-21 components. After the housing was removed using a milling machine, the internal experiment sections were examined. All eight fiber-optic sensors were recovered, cut, and stored. The silicon carbide thermometry, temperature sensor, pressure sensor, lower spacer, and selected pressure and temperature cable sections were also removed and stored. The metal bellows of the pressure sensor was found to be plastically deformed, indicating that it had been properly pressurized during irradiation and generally behaved as expected. X-ray diffraction analysis of a section of one of the irradiated inductor cores within the pressure sensor was performed and confirmed the presence of phase-pure alpha ferrite (i.e., no unexpected phase transformations). Inductance testing was performed on the irradiated pressure sensor cores using an unirradiated test coil, and DC resistance measurements of the transceiver coils were also performed. The measurements with irradiated inductor cores assembled inside unirradiated coils showed slightly reduced inductance compared to measurements made with unirradiated cores, but the difference was not sufficient to explain the more significant reductions in inductance that were observed in-pile. Therefore, it is suspected that degradation of the inductor coils (specifically the wire wrapping) is responsible for the reduced inductance observed in-pile.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS1967

Series transistors isolate amplifier from flyback voltage

Circuit enables high sawtooth currents to be passed through a deflection coil and isolate the coil driving amplifier from the flyback voltage. It incorporates a switch consisting of transistors in series with the driving amplifier and deflection coil. The switch disconnects the deflection coil from the amplifier during the retrace time.

Banks, W.↗

NASA NTRS1971

Measured losses in superconductor magnets for 60-Hertz ac operation.

Results of an experimental study of electrical losses in superconductor magnets. Preliminary 60-Hz ac loss data are presented for coils constructed of Nb3Sn ribbon, Nb-Ti cable, and multifilament Nb-Ti. Losses have been measured for different size coils up to approximately 20 cm in diameter. Of the conductor types tested, Nb3Sn ribbon has the lowest losses for ac operation. In Nb3Sn-ribbon coils of different sizes, the loss per unit length of conductor is shown to decrease with a decrease in the rate of change of current and to increase, in general, with increase in coil size. An important aspect of the study is the high degree of repeatability of the data.

Hamlet, I. L.↗

NASA NTRS1973

Characteristics and performance of a superconducting bumpy-torus magnet facility for plasma research

The NASA Lewis bumpy-torus facility consists of 12 superconducting coils, each 19 cm i.d. and capable of 3.0 T on its axis. The coils are equally spaced around a toroidal array with a major diameter of 1.52 m; they are mounted with the major axis of the torus vertical in a single vacuum tank 2.6 m in diameter. Tests of the facility mapped out its magnetic, cryogenic, vacuum, mechanical, and electrical performance. The design value of the maximum magnetic field on the magnetic axis, 3.0 T, was reached and exceeded. A maximum magnetic field of 3.23 T was held for a period of 60 minutes. When the coils were charged to a maximum magnetic field of 3.35 T, the coil system went normal without apparent damage or degradation of performance.

Roth, J. R.↗

NASA NTRS1973

Driving lamps by induction

An electrodeless lamp circuit with a coil surrounding a krypton lamp is driven by an RF input source. A coil surrounding a mercury lamp is tapped across the connection of the input central to the krypton-lamp coil. Each coil is connected in parallel with separate capacitors which form resonant circuits at the input frequency.

Laue, H. H.↗

NASA NTRS1975

Superconducting magnet and cryostat for a space application

The paper describes the design concepts, development, and testing of a superconducting coil and cryostat for an orbiting superconducting magnetic spectrometer. Several coils were subject to overall thermal performance and coil charging tests. The coils have low but persistent currents and have proven themselves to be rugged and reliable for mobile balloon flights. Satellite experiments will be conducted on a new, similar design.

Pope, W. L.↗

NASA NTRS1977

Load regulating latch

A load regulating mechanical latch is described that has a pivotally mounted latch element having a hook-shaped end with a strike roller-engaging laterally open hook for engaging a stationary strike roller. The latch element or hook is pivotally mounted in a clevis end of an elongated latch stem that is adapted for axial movement through an opening in a support plate or bracket mounted to a structural member. A coil spring is disposed over and around the extending latch stem and the lower end of the coil spring engages the support bracket. A thrust washer is removably attached to the other end of the latch stem and engages the other end of the coil spring and compresses the coil spring thereby preloading the spring and the latch element carried by the latch stem. The hook-shaped latch element has a limited degree of axial travel for loading caused by structural distortion which may change the relative positions of the latch element hook and the strike roller. Means are also provided to permit limited tilt of the latch element due to loading of the hook.

Appleberry, W. T.↗

NASA NTRS1977

Basic coaxial mass driver reference design

The reference design for a basic coaxial mass driver is developed to illustrate the principles and optimization procedures on the basis of numerical integration by programmable pocket calculators. The four inch caliber system uses a single-coil bucket and a single-phase propulsion track with discrete coils, separately energized by capacitors. An actual driver would use multiple-coil buckets and an oscillatory multi-phase drive system. Even the basic, table-top demonstration system should in principle be able to achieve accelerations in the 1,000 m/sq sec range. Current densities of the order of 25 ka/sq cm, continuously achievable only in superconductors, are carried by an ordinary aluminum bucket coil for a short period in order to demonstrate the calculated acceleration. Ultimately the system can be lengthened and provided with a magnetically levitated, superconducting bucket to study levitation dynamics under quasi-steady-state conditions, and to approach lunar escape velocity in an evacuated tube.

Kolm, H. H.↗

NASA NTRS1977

Potential damage to DC superconducting magnets due to the high frequency electromagnetic waves

Experimental data are presented in support of the hypothesis that a dc superconducting magnet coil does not behave strictly as an inductor, but as a complicated electrodynamic device capable of supporting electromagnetic waves. Travel times of nanosecond pulses and evidence of sinusoidal standing waves were observed on a prototype four-layer solenoidal coil at room temperature. Ringing observed during switching transients appears as a sequence of multiple reflected square pulses whose durations are related to the layer lengths. With sinusoidal excitation of the coil, the voltage amplitude between a pair of points on the coil exhibits maxima at those frequencies such that the distance between these points is an odd multiple of half wavelength in free space. Evidence indicates that any disturbance, such as that resulting from switching or sudden fault, initiates multiple reflections between layers, thus raising the possibility for sufficiently high voltages to cause breakdown.

Gabriel, G. J.↗

NASA NTRS1977

The magnetic attitude control of the Atmosphere Explorer-E spacecraft

The Atmosphere Explorer-E spacecraft was launched in November 1975, as the last of the Atmosphere Explorer series. It is a dual spin satellite and has on-board magnetic coils to maintain the spin axis of the spacecraft within 2 degrees of orbit normal. There is a constraint on the total angular momentum to keep it at a constant level, at around 1200 in-lb-sec +/-10 percent. On the previous AE satellites, the attitude and momentum were controlled separately, with dipoles mounted parallel to the spin axis for pure attitude control, and with coils in the spin plane to desaturate the momentum wheel. Due to the near-equatorial orbit of the AE-E spacecraft, spin axis coils would be inefficient, because the dipoles would have been closely aligned with the geomagnetic field vector. For this reason it was decided to control both attitude and momentum magnitude with dipoles in the spin plane. However, for spin plane coils the attitude and momentum control are strongly coupled, which required a special control theory to be worked out.

Grell, M. G.↗

NASA NTRS1978

Design study of superconducting magnets for a combustion magnetohydrodynamic /MHD/ generator

Results are presented for a trade-off and preliminary design study on concepts of a superconducting magnet system for a combustion MHD generator test facility. The main objective is to gain insight into the magnitude of the project in terms of physical characteristics and cost. The net result of a first-phase evaluation of attractive design alternatives is to concentrate subsequent efforts on (1) a racetrack coil geometry with an operating temperature of 4.2 K, (2) a racetrack coil geometry with an operating temperature of 2.0 K, and (3) a rectangular saddle coil geometry with an operating temperature of 4.2 K. All three systems are to produce 8 T, and use NbTi superconductor and iron for field enhancement. Design characteristics of the three systems are described. It is shown that the racetrack and rectangular saddle coil geometries seem most suitable for this application, the former because of its simplicity and the latter because of its efficient use of material. Advantages of the rectangular saddle over the two other systems are stressed.

Thome, R. J.↗

NASA NTRS1979

Overview and outline of Mass-Driver Two

An overview of the Princeton-M.I.T. second mass-driver is presented. Mass-Driver Two is a 13.1 cm caliber system which uses a two coil superconducting bucket and a two-phase in quadrature drive system. Discrete drive coils are individually energized with timing supplied by position-sensing optical detectors. Intermediate energy storage is provided by sector capacitors which are recharged every half cycle by an external power source. A vacuum environment is provided for the superconducting bucket by a 4 inch ID glass pipe with the drive coils surrounding it. Magnetic flight is generated by eddy current repulsion from six copper guide strips lining the glass pipe. The length is 2.5 meters equally divided between acceleration and deceleration sections. Nominal acceleration is 5000 m/sec per sec giving a maximum bucket velocity of 112 m/sec. Regenerative braking is used to decelerate the bucket. Current densities of 25 sq cm are achieved in the superconducting bucket coils and are maintained by a cryogenic service station.

Oneill, G. K.↗

NASA NTRS1979

Mass Driver Two - Cryogenic module

The cryogenic module of Mass Driver Two comprises a 3.25 inch (82.55 mm) OD bucket with two 44 kilo-ampere-turn coils made with .028 inch (.71 mm) diam niobium-titanium multi-filamentary cable in a copper matrix, impregnated with lead alloy for thermal inertia, as well as the service station to refrigerate, energize and eject the bucket. The station is housed in a six inch flanged pyrex cross which connects to the four inch pyrex tube of the mass driver itself. The bucket is refrigerated by being forced against a copper braid cradle attached to the bottom of a liquid helium reservoir which protrudes into the cross from above. The bucket is energized inductively by turning off two superconducting coils which are also attached to the helium reservoir, and which have maintained the correct flux linkage through the bucket coils during their cool-down through the critical temperature. Once charging is completed, the clamping pressure is released and the bucket is injected into the mass driver by means of two normal-conductor pulse coils surrounding the horizontal branches of the cross.

Fine, K.↗

NASA NTRS1980

IMP 8. Volume 1: EM field experiment

The electromagnetic fields experiment on IMP-J used two electric dipole antennas and a triaxial search coil magnetic antenna to sense the electric and magnetic field of plasma waves in space. The electric dipole antennas consisted of a fine wire, 0.021 inches in diameter, with a nominal extended tip-to-tip length of 400 ft. The outermost 50 ft. of each element was conducting and the rest of the antenna was covered with an insulating coating. The search coil antennas each consisted of a high mu core with two separate windings of 40,000 turns each to sense ac magnetic fields. The search coils had a length of 18 inches tip-to-tip and are mounted on the end of a boom. The axes of the x prime and y prime search coil antennas were parallel to the x prime and y prime electric antenna axes.

Source record↗

NASA NTRS1981

DC-magnetic field vector measurement

A magnetometer experiment was designed to determine the local magnetic field by measuring the total of the Earth's magnetic field and that of an unknown spacecraft. The measured field vector components are available to all onboard experiments via the Spacelab command and data management system. The experiment consists of two parts, an electronic box and the magnetic field sensor. The sensor includes three independent measuring flux-gate magnetometers, each measuring one component. The physical background is the nonlinearity of the B-H curve of a ferrite material. Two coils wound around a ferrite rod are necessary. One of them, a tank coil, pumps the ferrite rod at approximately 20 kilohertz. As a consequence of the nonlinearity, many harmonics can be produced. The second coil (i.e., the detection coil) resonates to the first harmonic. If an unknown dc or low-frequency magnetic field exists, the amplitude of the first harmonic is a measure for the unknown magnetic field. The voltages detected by the sensors are to be digitized and transferred to the command and data management system.

Schmidt, R.↗