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AN INTERACTIVE COMPUTER PROGRAM FOR THE DESIGN AND COSTING OF MAGNETS
K. Thompson
To cite this version:
K. Thompson. AN INTERACTIVE COMPUTER PROGRAM FOR THE DESIGN AND COSTING OF MAGNETS. Journal de Physique Colloques, 1984, 45 (C1), pp.C1-871-C1-874.
�10.1051/jphyscol:19841177�. �jpa-00223652�
Colloque C I , supplkment au n" 1, Tome 4.5, janvier 1984 page CI-871
K.M. Thompson
Argonne NationaZ Laboratory, Argonne, IZZinois 60439, U.S.A.
RQsumE
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On d6crit un programme pour ordinateur, qui a pour but la concep- tion, ainsi que l'estimation des coilts, d'aimants conventionnels de types diffdrents. Le programme, en language BASIC, est compos6 de quatre sections, dont les d6tails spscifiques seront d6crits sur un exemple.Abstract
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A computer program is being written to aid in the design and cost estimating of a number of different types of conventional magnets.The program is composed of four separate sacdons and written in BASIC.
The features of each section are explained and an example is described.
Introduction
In particle accelerator environments, it often becomes necessary to quickly design and estimate the costs of conventional magnets. These magnets may be required for a proposed accelerator ring, beam line, or spectrometer. Often the estimated costs influence the choice of design of the overall project, and, therefore, it is desirable ta qwickly determine the magnet costs so that each design cycle of the total system can be as short as possible.
The designs developed here consider only the strength or gradient of the central magnetic field and develop core and coil designs to produce the required field.
There are still a large number of parameters which must be considered for each of these calculations and even an experienced magnet designer could have difficulty in consistently defining each one during cansecutive attempts. The code assisting him in this work must, therefore, maintain the consistency of the parameters from run to run but also allow the operater to freely change them when he desires.
When the calculations are finished the program must be able to provide a complete listing of all input as well as output parameters. These listings should contain a description of each parameter along with the associated units and it should be clear which parameters were explicitly changed by the operator during the current run.
A system of computer programs, MAGNET, is now under development at Argonne to achieve the above objectives. It is being written in BASIC for a Hewlett Packard 9845T desktop oomputer oontaFning 187 Khytes ef memory, an internal thermal line printer, and two tape drives. This system of programs will be discussed in the following sections.
Coil Conductor Section
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COILCALCThis section is maant to be used to accurately define the conductor to be used in the magnet being designed. It provides operating parameters for conductors having minimum and maximum conductor areas due to the applications of the dimensional tolerances. A conductor may also be derived only from limits on certain operating parameters and coil configuration values. The operator may choose, for example, the operating current and voltage, the number of turns in the coil, the average turn length, the numher of turns per coolant circuit, the coolant supply temperature, and the coolant temperature and pressure gradients. The code will then define the wnductor size requirwd to nmtch all of these requirements.
The equations and the input and output formats used in this section are described in Keference 1.
*work supported by the U.S. Department of Energy
Article published online by EDP Sciences and available at http://dx.doi.org/10.1051/jphyscol:19841177
C1-872 JOURNAL DE PHYSIQUE
Magnet Design Section
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DESIGNThis section derives preliminary designs for several types of magnets. It can design picture frame or H-frame dipole magnets with side yokes of equal or non- equal thicknesses- It also designs quadrupoles, sextupoles, and octupoles. Each of these magnet types may be excited with direct or sinusoidal currents (including pulsed half sine waves). The dipole magnets have a straight or curved axis and there may or may not be a vacuum chamber either inside the gap, like the SNS ring magnets, or around the w r e , like the ring magnets for the FNAL booster or the RCS at Argonne.
In each magnet type the effective length and usable, transverse gap size may be defined as input. The latter is commonly the gap size requested by the accelerator physicist. The designer may choose the oanductor size and the coil turn configuration
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number of layers, number of turns per layer, number of turns per cooling circuit, and effective number of turns. The last coil parameter above is used to calculate the number of conductors that are electrically connected in parallel. This parameter has been very useful in reducing the maximum operating voltage for magnets excited with alternating currents. There are many time consuming details that must be addressed in the final design in order to equalize the flux linkage and resistance of each parallel path; this code, however, does not address these equalizing details but only assumes it can be done since it has been done in the past (RCS at Argonne, for example 2 ). The operator may also define coil insulation thickness, clearances between the coil and the core, and the flux density inside the yoke across the narrowest sections. He may also define the locations of the mgnetic field affective edges with respect to the pole edges.From these parameters plus a few others, RESIGN will calculate the coil and core dimensions and the operating parameters for the electrical and coolant systems.
The parameters listed are sufficient to design a power supply (ac or dc as required) and for a draftsman to start the actual drawings for a new magnet.
As the wde naw exists the coil turn configuration is manually defined but it will be automatically determined in future versions. To do this a maximum operating voltage or an operating RMS supply current must be. specified. Using this information and the chosen conductor size the code will develop a coil design starting with a single, series wound conductor and progressing to coils with increasing numbers of parallel connected conductors. In this process the distance between poles may be enlarged slightly to match the quantized number of ampere- turns for a given coil solution.
Cost Estimating Section
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ESTIMATEThis section is not fully implemented yet but a prototype code has been written to develop some of the logic and has been used successfully on several projects.
When complete, this program section will construct two tables. One will be a list of unit costs, planned excesses to take care of looses and waste, and unit efforts (man-hours required to stack one lamination ar make one bend of the coil conductor, for example). The values in this list are originally defined by the program and are based an recent experience at Brgoune. They are, however, being revised constantly as better data becomes available. The operator will be able to change any entry in this table as required for the specific case at hand. The second list will contain the estimates of the fabricating costs broken down into the purchased raw materials, parts and tooling, aad the effort required for the design, construction, and testing. The effort will be listed for each major activity broken down into the various types ~f s k i l l s like engineers, draftsmen, mechanical technicians, coil tuinders, machinists, riggers, etc.
An example table of the cost estimate6 far 100 dipole magnets needed for an accelerator ring is shown in Table
I.
This was produced by the prototype version of ESTIMATE and does not contain all af the detail described above. It does,TABLE I. Prototype of ESTIMATE
Quantity $1000
Cost estimates for the 100 magnets:
Silicon steel sheet Stamping die(s) Laminations
Stainless steel parts fabrication Conductor and insulation
Coil fabrication plus tooling Misc. hardware and tooling items Shipping
Labor costs:
1019378 kg 1835
2 52
90 30 50 948 18932 kg 565 207367 m 6 20 57904 mhr 1638 323 1117315 kg 134 Partial total:
6115
Core assembly 128 mmo 50 4
Coil installation 61 mmo 239
Final acceptance tests 20 mmo 80
Partial total: 822
Contingency 20% 1387
TOTAL : 8325
Output Section
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OUTPUTThe output from each of the three previaus wcblons 16 of three forms: 1) The results may be listed on the CRT or internal thermal printer for on-line viewing, 2) The results may be stored on tape for later print out, and 3) Some of the parameters may be put into common storage to be used by the following program sections.
This fourth section has not yet been written; it will, however, eventually allow all files stored on tape in the other three sections to be printed on all available devices. In our particular case this includes the CRT, the internal thermal printer, and a daisy wheel printer.
In addition to the printiag function, this section will also be capable of making scale drawings of end, side, or top views of the magnet designs with the scale defined by the operator. Partial section drawings will also be available complete with the major dimensions.
Using MAGNET
Suppose you are to design and estimate the costa for tBe magnets for a 30 Hz rapid cycling synchrotron ring. The lattice uses two different combined function dipoles and incarporates 100 of each that must be electrically connected in series. Also 30 defocusing quadrupoles and 15 focusing quadrupoles must be included and connected in series with a sepazate porn supply. Using DESIGN the operator would develop a design for one of the dipoles and one of the quadrupoles choosing coil configurations which keep the maximum operating voltage drops across these magnets at desired levels. The second magnet of each type is then designed but this time the supply currents must be the same as for the first magnet so that the magnets of each type can be connected in series. After the final design is obtained for each magnet the results are stored on tape.
C1-874 JOURNAL
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PHYSIQUEUsing ESTINATE, the operaur will a d i t the unit cost an& unit effort table to suit the specific application. Then he will recall the design data for each magnet and do the cost calculatiena. The xesulting lists are stored on tape as each is completed.
Finally, OUTPUT -is used to document the designa end cost estimates by printing out all files. For this particular case involving four magnets, this would involve at least eighteen pages. In addition to this printed output a dimensioned, partial section drawing for each magnet can be made to provide visual representations of the final designs.
Conclusions
The use OX DESIGN and the prototype version of ESTIMATE has proven to greatly simplify the preliminary design process for conventional magnets used in acceleratox rings
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SNQ and L W F 11, for exampla. Single parameters can easily be changed, which allows the operator to clearly demonstrate how the final costs depend on the parameter of choice* When the automatic coil configuration defining section is fully operational, this process will be even more informative. The effects on a design can be studied for changes like changing the bore size, placing the vacuum chamber inside the magnet bore rather than around the outside surfaces of the core, or bending the magnet axis or keeping it straight. The associated costs of the various designs can then be found and subsequent cost comparisons can be made. As a result, even a novice magnet designer should be able to develop realistic designs and even do some optimizing.The ceal vdue of this program is not the exact design that results for a given magnet, although it can be very close to a final form, but that ALL parameters that are used in the calculatians are listed and are, .therefore, available for examination at any time. The accuracies of the cost estimates depend, of course, on the accuracies of the associated unit cost and unit effort table.
References
1. K. Thompson, "An Interactive CBde far Optimization of Water-Cooled Conductors," Proceedings of the Fourth International Conference on Magnet Technology, Report CONF-720908, p. 725 (1972).
2. M. Foss, K. Thompson, R. Lari, and J. Simpson, "The Design of the Zero Gtadient Synchrotron Booster
