High reliability prototype quadrupole for the Next Linear Collider

The Next Linear Collider (NLC) will require over 5600 magnets, each of which must be highly reliable and/or quickly repairable in order that the NLC reach its 85% overall availability goal. A multidiscipline engineering team was assembled at SLAC to develop a more reliable electromagnet design than historically had been achieved at SLAC. This team carried out a failure mode and effects analysis (FMEA) on a standard SLAC quadrupole magnet system. They overcame a number of long standing design prejudices, producing 10 major design changes. This paper describes how a prototype magnet was constructed and the extensive testing carried out on it to prove full functionality with an improvement in reliability. The magnet's fabrication cost will be compared to the cost of a magnet with the same requirements made in the historic SLAC way. The NLC will use over 1600 of these 12.7 mm bore quadrupoles with a range of integrated strengths from 0.6 to 132 Tesla, a maximum gradient of 135 Tesla per meter, an adjustment range of 0 to -20% and core lengths from 324 mm to 972 mm. The magnetic center must remain stable to within 1 micron during the 20% adjustment. A magnetic measurement set-up has been developed that can measure sub-micron shifts of a magnetic center. The prototype satisfied the center shift requirement over the full range of integrated strengths.